OK, I might get roasted for this, but here goes….
I’m creating a set of decorative louvers for a 12/12 gable end- my idea is to create two ‘rails’ on each side of the gable (45 degrees exactly), with a groove where the louvers can fit. Because I want the louvers to be angled downward (when viewed from the front) at 30 degrees, this means the rails would have a groove cut at 45 degrees (from horizontal) and slanted at 27.5 degrees (from vertical, to create downward angle).
I have a Bosch 4100-09 table saw, and a DeWalt miter saw (non-sliding). A saw with a radial function would probably be the best choice, but can a table saw be used with a dado blade and turned to a 27.5 degree angle? Any other suggestions?
Replies
I've done compound dado cuts with my unisaw and cled set up for the specific angle.
I'm not familiar with the Bosh saw. I would guess you could build a cross cut sled that fits the miter gauge slots and go from there. That would be a whole lot safer IMO. I have done it with a RAS, but it was way scarey.
angled dados
Would there be someway to do this with a router set up of some kind? Have no idea how this could be done. It's just that I've seen my guy do some amazing stuff before. Just a thought.
I've never had any trouble cutting angled dados. But I'm guessing that you want some SPECIFIC angle.
Actually, I'd considering setting up a jig with a large Dremel or a baseless router, using a router dado bit. Then you could build the jig to hold the angle you want.
I did a bit more digging today, including a call to Bosch- they don't recommend using a dado blade and making angle cuts with their 4100 saw- near as I can guess, it probably has more to do with the weight of a stacked dado blade spinning at an angle- pretty hard on the motor.
I have considered using a router (I have a fixed base router and a decent table), but can't figure out how I'd create the right angle cut.
The gable is 90 degrees, so each rail is 45 degrees- I want the louvers to tilt forward at 30 degrees- this means each end of the louvers enter the rail at a 27.5 degree angle (I found this through trial and error- not trigonometry- I'm not that smart). Therefore, a router would need to be baseless, and have some kind of rig that holds it at that angle as the stock is fed through it (or vice versa).
Geez, this seems a lot more complicated than it needs to be. There's gotta be a simpler solution....
Easier?
Beats me if it's easier, but.
Use blocks to make up the spaces between the louvers. Block, louver, block, louver..........
You'd be doubling up the jamb somewhat, but any exterior trim will mask that.
Take the base off the router and move the router, not the workpiece. Exercise in jig building.
The trick is getting that angle without having the router body interfere -- you'll need a long bit, and it will cause some wear of the router end bearing.
Depending on how thick your slats are, what about setting up your table saw and doing a progressive 'nibble' process? You'll have to guage the depth of the blade after each series of cuts but like one poster suggested, use a sled locked into your miter slots and put a key block on it where the previous cut fits over the key block to maintain consistent spacing of cuts. Run your first cut on both pieces then calibrate the depth of your blade to properly align with the bottom of the first cut for the second series of cuts and repeat as necessary until you have the width of dado you need for the slats to fit. Not sure if this is clear but I can see it in my head clearly enough...
I created the first set by using the table saw and laying the blade back at 27.5 degrees, and made a series of cuts for each groove in each rail with the miter gauge at 30 degrees (I think this is what Homewright was suggesting...?). Since the louver/slats are ~3/8", it took 3 passes per groove...about 12 grooves per rail, x2 rails...a LOT of passes! (And that doesn't count the first trial set, which resulted in an unacceptable angle). With all the guards removed, this gets pretty dicey...I would really like to keep my fingers...
I have about 4 more sets of louvers to create, and was hoping a dado blade would reduce the number of required cuts- alas, this doesn't seem to be an option. Creating a jig for a baseless router might be an option, with some creativity....otherwise, creating a series of angle-cut blocks and alternating them with the louvers might be an option, too.
I appreciate the creative ideas, and the patience.