Three ways to cut dadoes. Each has its place. Here’s when to use what.
Table Saw Dado Stack
If you’ve got one, this is usually fastest. Stack the blades to your width, set depth, run the piece through. Done.
Downsides: dado stacks are expensive. Some table saws can’t fit them. Changing widths means restacking blades.
I use this for production work – lots of identical dadoes.
Router Method
Straight bit, guide fence or template. Very accurate. Works on pieces too big for the table saw.
Multiple passes for wide dadoes. Templates make stopped dadoes easier. More setup time but flexible.
My go-to for one-offs and odd sizes.
Dado Plane
Hand tool route. Slower but satisfying. No dust collection needed. Quiet.
Takes practice to get consistent. Not great for production. But for fine furniture where you want hand-tool marks? Perfect.
What Actually Matters
Depth: half the thickness is typical. Go deeper and you weaken the piece.
Fit: should slide together snug but not forced. Test with a scrap first.
Square: check with a combination square. Out-of-square dadoes cause visible gaps.
Stopped dadoes – the ones that don’t go all the way through – look cleaner. Square the corners with a chisel, notch the shelf to fit.
