When using a router, you want to avoid taking too deep a cut. It can
create excess chipout and, in some situations, can be dangerous. So when I want
to rout a dado or groove that's more than a 1/4" deep, I take multiple
passes.
I know.
It's easy enough to change the height of the bit between passes. But with some
routers, changing the height of the bit also slightly changes the position of
the bit relative to the base. (This means you could end up with an unwanted
shoulder inside the dado.) And besides, I've come up with a way of using depth
stops that lets me avoid the extra setups.
To rout a deep dado with one setup, I
use a set of depth stops or plates that are carpet taped to the base of the
router, refer to Fig. 2 at right. Two of these plates are made from 1/8"
hardboard, and a third is 1/16"-thick plastic laminate. All three stops have a
hole drilled in the center for the bit to fit through.
Before you add the depth stops to the
base plate, the first thing to do is adjust the height of the router bit to
match the finished depth of the dado, as in Fig. 1. (Once the bit is set, leave
it alone.) Then carpet tape the auxiliary stops to the base of the router (Fig.
2).
After the first pass, simply "lower"
the bit during successive passes by removing one stop (Fig. 3). The final pass
(after removing the laminate depth stop) will be a 1/16"-deep skim cut that will
leave a clean dado at just the right depth.
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