How do I make an inch long cut in the middle of an inch thick board without cutting the wood beyond both ends?

Question

I need to cut a thin rectangle type "stick" out of a wooden board. I can use a table saw the cut the two long sides, but I don't know how to cut the end, shaped something like an "H".

Imagine the two vertical lines of the H as the cuts I already made with the table saw. How do I reach in there and cut the small horizontal line in the "H"?

Answer 1

if its super important take it to a shop with a water jet or laser

Answer 2

try a router

Answer 3

use a drill the same size as the depth of your blade to give

you a start hole.

Answer 4

the best thing to use is a jig saw for those types of cuts. I don't know how handy you are but if you don't have a jig saw you can use a circular saw to make the cuts but in order to do this you need to be very careful or you will cut your fingers off.

1) pull the blade guard back

2) very carefully start the saw and ease it into the area that you need to clear

3) take a rasp or file and smooth out your edges

Answer 5

First drill a starter hole in the center of where the cut will be, then use a jigsaw to cut out the opening.  I have done this myself, and I'm kind of a dork with power tools, so it is an easy way to do the job.

Answer 6

You can make a plunge cut with a handheld jigsaw.  Hold the saw at a foward tilt with the front of the foot touching the board and slowly tilt it backward, easing the tip of the blade into the board along the line you want to cut.  Cut one direction to the end, then turn the saw around and cut the other direction.  Practice on a scrap board until you can do it easily.  You can also use the jig saw to finish the side cuts.

Answer 7

buy a cheap hand held coping saw...

Answer 8

If a table saw is the only saw available....

Continue to cut out the inside of the "H" just like you did to get the vertical 'legs' as you described.  Just move the fence over a bit, so you are cutting into more of the stock needing to be removed.  If the "H" is the same size all the way around, you can set one stop for the length, and then just flip the board to make all the cuts.  It'll take a little time, and you'll want to chisel the horizontal flat probably....but it works.

A faster method is to drill a hole at the inside corners (large enough for a jigsaw blade to fit into), and then use a jigsaw to cut across, and notch the corners.

The best looking results can be achieved with a router, and a good bit.

Oh, by the way... if this cut is only an inch into the board... and the board isnt very long, you could set it up on a vertical fence.  Think a really tall miter gauge rail, and you get the idea.  (this would also give you the flattest edge on the 'horizontal')

Have Fun