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(sr_wood) wrote in message . com...
I'm making a particle board cubbie storage unit for my wifes
classroom. I've decided that the best way to design the unit is to
make the shelves interlocking, but can't think of a great way of
making the slots. The storage unit will have 15 total cubies all 12" x
12" x 12" (5x3). My first thought was to cut 4 slots on the 2
horizontal shelves half way through and then make 2 slots on each of
the 5 vertical deviders half way through on the table saw. But I'm not
sure how to finish off the cut or if it is a safe way to get the job
done.
Has anyone done this kind of thing before? Would a dado blade work
better? A jig saw? A router? This may be a no brainer, but do you make
the slots the same size as the particle board? (23/32)

I would be very grateful for any ones help, and you would make a hero
out of me with my wife.

Thank you,
Don

Don: first, some questions:

1) What equipment/tools do you have access to? (Cutting 6" deep slots
on the TS is not possible with a 10" blade. Part of it can be
done--in one pass with a dado blade and a big honkin' saw, or two
passes with a stopped cross-cut--with the boards flat on the table,
but you'll have some area at the center of the board which will have
to be hand-cut, chiseled or routed square.)

2) What will be stored in the cubbies--heavy or light items? (Particle
board is notorious for bending under weight and one end of each cubbie
in your design will be unsupported. Unsupported PB is also more
likely to break if even a preschooler leans on it.)

I would cut dados across the horizontal shelves and fitting shorter
vertical dividers in the dados. This would make a stronger unit.
Might be faster, too. Put a back panel on it (to keep it from
racking) fitted in a rabbeted edge (to keep things neat). Remember to
subtract the thickness of the back from the width of the center shelf
and dividers, and add the combined depths of the dados to their length
and heigths (respectively).

And yes, the dados or slots should be the same size as the board.

Keep us posted, hero.

Dan