Tom Gardner (nospam) wrote:
I need the best, cheapest way to cut a 1-1/2" wide by 3/64" deep slot
across a KD Beech block

In terms of force applied and energy used, two of the recommendations
are appealing
and can be hybridized to make a solution similar to the Roy Underhill
style of work.

Saw the edges of the slot, then chisel out the waste.

Two thin-kerf blades in a dado-like setup (with washers as spacers
instead of chipper blades)
can define the slot edges on a table saw. Then a jointer with custom
blades can hog out
the waste. The benefit is: buried in a cut, the thin-kerf blades will
cut true and have
plenty of cooling, and only make a little sawdust. Then the jointer
blades will take out
big chunks of toothpick-shaped waste, taking very little energy
(because the fibers
are already cut at the ends).

In terms of energy required and stress on the wood, there is one better
way to do the
job, with a succession of passes with the right kind of plane (with
knives to slit
the edge and a rabbet iron to hog the waste, it can ALL be little
toothpick-waste
with no sawdust). Is it acceptable to set up several shapers together?