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Used to cut all my dados with a stacked set, switched to a router jig last month and I'm not going back
For 8 years I ran every cabinet dado on my table saw with a stacked dado set, shimming it to hit 3/4 inch ply. Half the time the ply was undersized by a hair and my joints had slop I had to hide with glue and sawdust. A guy at the woodworking swap in Grand Rapids showed me a simple router jig he built from scrap MDF and two guide rails, total cost was about $40. I tried it on a set of shop cabinets last month and every dado came out dead flat and dead sized, no shims, no test cuts after the first setup. Setup takes me maybe 10 minutes but the cuts themselves are way faster because I'm not fighting tearout on the backside. Curious if anyone here has gone the other way and stuck with the table saw, or if you use a jig like mine, what do you do for stopped dados?
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