How to Create Dados with a Router Bit

When it comes to cutting dados—those precise, flat-bottomed channels used for joinery—many woodworkers turn to a table saw with a dado blade set. But if you don’t have a dado set or prefer a more versatile option, a router with the right bit can do the job just as well. Here’s how to create clean, accurate dados using a router.

High Production Straight Plunge Cutting Router Bits cut laminated particle board up to 800 inches per minute feed rate at 18,000 RPM. (Rate may change depending on material and CNC machine type.) 

Choosing the Right Router Bit for Dados

For routing dados, you’ll need a straight bit, spiral upcut bit, or a specialized dado bit. Here’s what to consider:

• Straight Bits: A carbide-tipped straight plunge bit is an economical choice for shallow dados in plywood and hardwoods.
• Spiral Upcut Bits: If you want cleaner cuts with better chip evacuation, a spiral upcut bit is ideal, especially for deeper dados.
• Two-Flute or Three-Flute Dado Bits: These bits are specifically designed to produce flat-bottomed dados with minimal tearout.

Step-by-Step Guide to Routing Dados

1. Mark Your Dado Location

Use a pencil and a square to mark the start and end points of your dado on the workpiece.

2. Set Up a Guide Fence

Clamp a straightedge or a guide fence parallel to your cut line to ensure a perfectly straight dado.

3. Select the Correct Bit Size

Match the router bit diameter to the width of your dado. If needed, make multiple passes to achieve the desired width.

4. Adjust the Router Depth

Set your router’s plunge depth to match the depth of the dado, typically about 1/3 the thickness of the material.

5. Make Multiple Shallow Passes

Rather than cutting the full depth in one pass, take multiple shallow passes to prevent burning and ensure a smooth cut.

6. Clean Up the Dado

Once routed, inspect the dado for any rough edges and use a chisel or sandpaper to fine-tune the fit if necessary.

Use a Flush Trim Plunge Template Router Bit for Dado Clean Out

Tips for Perfect Dados with a Router

• Use a downcut spiral bit for minimal tearout when routing dados in veneered plywood.
• If routing multiple identical dados, use a dado jig for repeatable precision.
• Always test on scrap wood before cutting into your final workpiece.

Final Thoughts

Using a router to cut dados is an excellent alternative to a table saw with a dado set. With the right router bit and setup, you can achieve professional-quality results for cabinets, shelving, and other woodworking projects.