To create the dado cuts for the interior wall, you must configure your table saw with a dado stack width of 13/16 inch and a cut depth of approximately 3/8 inch. Position your rip fence to place the dado exactly 2 1/4 inches from the end of the board, ensuring the two side pieces are cut as a mirrored pair rather than identical copies.
The success of this joint relies on precise blade configuration and board orientation. Specifically, cutting the sides as mirror images is essential to ensure the interior wall slots align perfectly across from one another upon assembly.
Configuring Your Equipment
Establishing the Width
Set your dado blade stack to a width of 13/16 inch.
This specific measurement is required to match the actual thickness of the pine stock being used for the interior wall. A tight match ensures a sturdy join that does not require excessive glue or fasteners to hold its position.
Setting the Depth
Adjust the height of your blade to create a cut depth of approximately 3/8 inch.
This depth provides enough mechanical support to hold the interior wall effectively without compromising the structural integrity of the long side pieces.
Positioning the Fence
Set your saw fence to position the dado 2 1/4 inches from the end of the board.
This measurement dictates the specific location of the interior wall within the feeder. Verify this distance carefully before making your first cut.
Critical Technique: The Mirrored Pair
Avoiding Identical Cuts
The most common error in this process is cutting both side boards identically.
You must cut the dadoes on the two long side boards as a mirrored pair. This means the boards are not interchangeable; they have a distinct left and right orientation.
Orienting Relative to the Floor
Reference the existing floor dado when setting up your cut.
The interior wall dadoes must be on opposite edges relative to the floor dado. If you cut them on the same edge, the slots will not face each other when the box is assembled, making it impossible to install the interior wall.
Common Pitfalls to Avoid
Misinterpreting "Mirrored"
Do not simply flip the board end-over-end if that places the cut on the wrong face.
You must ensure that when the "inside" faces of the side boards are facing each other, the dado slots align perfectly.
Ignoring Material Variance
While the recommended width is 13/16 inch, wood thickness can vary slightly.
If your pine is slightly thicker or thinner, the 13/16 inch setting may need micro-adjustment to prevent a joint that is too loose or too tight to assemble.
Making the Right Choice for Your Goal
To ensure your feeder assembles correctly, verify your setup based on your immediate objective:
- If your primary focus is Structural Integrity: Ensure the blade depth does not exceed 3/8 inch to keep the side walls strong.
- If your primary focus is Assembly Ease: Double-check that your boards are marked as left and right mirror images relative to the floor groove before cutting.
Measure twice and mark your orientation clearly to guarantee the interior wall slides perfectly into place.
Summary Table:
| Parameter | Specification | Purpose |
|---|---|---|
| Dado Width | 13/16 inch | Matches standard pine stock thickness for a tight fit |
| Cut Depth | 3/8 inch | Ensures structural support without weakening side walls |
| Fence Position | 2 1/4 inches from end | Sets the precise interior wall location within the feeder |
| Orientation | Mirrored Pair | Guarantees slots face each other during final assembly |
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