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1 Start with a piece of W'-thick oak, initially cutting it oversized to approximately 6W wide by 12" long. Plane the blank to 3/s" thick. Use a dado blade in your tablesaw to cut the Vs" dadoes 3/i6" deep, where shown on Drawing 4. To do this, attach an extension to your tablesaw's miter gauge. Next, clamp a stopblock to the extension, positioning it to make the edge of the first dado Va" from the end, and make the cut. (See Drawing 3.) After you have cut all the dadoes, trim the ends of the blank to reduce its length to 5Va". Rip the grille blank to make eight stiles 5/s" wide.

Note: The edge of the bottom dado is Vs" from the end of the blank.

cutting the grille stile blank cutting the grille stile blank

0 exploded view

33 base detail

Va" stopped chamfer, cut after assembly

Start and stop lines for chamfers

5/ie" hole

5/32" shank hole, countersunk from the bottom side

3/s" hole, centered, for threaded nipple

Ve" hardboard

3" hole, centered, with a Vi" rabbet Va" deep routed around bottom

Vi" hole, centered

  • 6 x Va" F.H.
  • s" stock

Ve x 37/ie" tempered hardboard disc wood screw

Vi" hole, centered

3/s" hole, centered, for threaded nipple

Secure grille to with silicone.

Ve" hardboard

3" hole, centered, with a Vi" rabbet Va" deep routed around bottom

's" stock

Ve x 37/ie" tempered hardboard disc wood screw

Va" stopped chamfer, cut after assembly

0 exploded view

33 base detail

Start and stop lines for chamfers

5/ie" hole

5/32" shank hole, countersunk from the bottom side mission lamp

□ grille assembly b bevel-cutting the top and base

3 circle cutting techniques q bolt clamp fixture the blade, and fit your tablesaw with a new wood or plastic insert. To make it into a zero-clearance insert, move the rip fence over the edge of the insert to hold it in place, set the blade angle at 14°, turn on the saw, and raise the blade through the insert. Shut off the saw, move the rip fence into its final position, and adjust the blade height to about IV2". Make the bevel cuts on the top surface of the base (E) by keeping the rabbeted side of the hole against the fence.

5For the top (F), completely lower the blade, change the blade angle to 12°, and then raise the running blade through the blade insert. You will have to adjust the rip fence and set the blade height to about 2]/z". Make the cuts in the top.

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