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Low profile slotter

5/26/21       
BH Davis  Member

Website: http://www.bhdavis.net

I need to run a horizontal slot, about 1/16" thick x 1/4" to 3/8" deep, into the bottom of a series of existing installed posts. The problem is that there is a railing system between the posts, and the distance from the bottom of the shoe rail to the floor surface is about 2-1/4". This would be a perfect use for my seldom used Crane undercut saw if it wasn't about 6" too tall !

I need something on the order of a plate joiner that can ride the floor surface while cutting the slot in the side post about 3/4" above floor level. Problem of course that is plate joiners are much too tall.

I'm racking my brain trying to think of an existing power tool that will fit but not making much headway. Anyone have any ideas? A miniature plate joiner would be perfect !!

Thanks,
BH Davis

5/26/21       #2: Low profile slotter ...
BH Davis  Member

Website: http://www.bhdavis.net

I wish we were able to edit posts here. On a second reading I noticed that I initially said "into the bottom of the post". This is misleading. The slot goes into the side of the post, near the bottom.

BH Davis

5/26/21       #3: Low profile slotter ...
Keith Newton

If all else fail, it sounds like a handsaw laying flat against the 3/4” spacer. Or a reciprocating saw guided the same. And or a multi-tool maybe?

5/26/21       #4: Low profile slotter ...
BH Davis  Member

Website: http://www.bhdavis.net

Yes......multi tool comes to mind. But even the Dremel, which is pretty small, is over 3" tall.

At this point it may come down to the hand saw on a spacer. Reciprocating saws are pretty wild when it comes to trying to hold them accurately on a line.

Thanks,
BH Davis

5/27/21       #5: Low profile slotter ...
Keith Newton

I have seen someone grind the tang from a Japanese saw to fit the recip, then with the saw set slow, holding the wider blade down with a finger get the control you need.

If you have a lot to make this worthwhile, I'm sure you could do it.

5/27/21       #6: Low profile slotter ...
MikeT Member

You could try a jamb saw, or a fein tool on top of a spacer.

Jamb Saw

5/27/21       #7: Low profile slotter ...
Mark B

What quality does the kerf have to be? I can imagine any type of recip (sawzall, multi tool) going anything other than hogging out some material if you need a clean/machined looking slot around the post. I could see a bunch of simple shop built options with a saw to hog the bulk out and come back with a simple router plane type affair (something as simple as a 1/4" chisel kerfed into a couple pieces of ply) to clean it up after the fact.

If its just a construction kerf its one thing but if you need a presentable kerf around the post it gets fussy. I'd be leaning towards your undercut saw for the faces that it works and then a hand option for the remainder.

5/27/21       #8: Low profile slotter ...
Pat Gilbert

I'm sure you already know to clamp a wood guide to the post and then use a Fein tool

5/27/21       #9: Low profile slotter ...
TonyF

Bernie:

Unless you have hundreds of these to do, I think what I might do is to get a cheap Japanese style saw from Home Depot, or wherever you can get one.

Make two blocks, one the thickness of the distance of the groove off of the floor, and one thicker to sit opposite. Screw or bolt the blocks, countersunk, through the saw, positioned such that the blocks also serve as your depth of cut gauge. Saw while holding the block against the floor, using masking tape to mask the floor against scratches.

Taping the post where the cut goes might help to get a cleaner kerf as well.

FWIW. Good luck.
TonyF

5/27/21       #10: Low profile slotter ...
rich c

An offset base on a trim router might work.

6/1/21       #11: Low profile slotter ...
Steve Member

" A miniature plate joiner would be perfect !!"
Its seems to me that my Ryobi DBJ 50 joiner is exactly that. Am I misunderstanding your requirement?

6/1/21       #12: Low profile slotter ...
BH Davis  Member

Website: http://www.bhdavis.net

Steve,

Yes......I fear I haven't explained it clearly enough. The tool has to fit UNDER shoe rail that is about 2-1/2" off the floor.

The suggestion of the offset trim router is a great idea. I will definitely be checking that out. It might just do the trick if I mount it on a plywood sub-base to raise the slotting cutter above floor level.

Thanks,
BH Davis

6/1/21       #13: Low profile slotter ...
Steve Member

B.H. First, your website and historical building with curved entry fence are fascinating.
Yes, oops, I should have re-read your second post. It appears manual cutting is going to be the burden. A non-flexible manual jamb saw seems to be in order given 2.5" clearance. Specifically, how many cuts will be needed?


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6/1/21       #14: Low profile slotter ...
BH Davis  Member

Website: http://www.bhdavis.net

Steve,

Thanks. I appreciate your taking note of the old business.......and now the old building as I finally sold that just over a week ago. I will miss it but once the fellow who bought my radius moulding business moved out last Sept. it was either look for a new tenant or lighten the load so to speak. I saved that building from the wrecking ball and then kept it for nearly 20 years. I don't feel too badly about passing it on to someone else to care for now. The new owner is going to make it into a house so that should be interesting to see happen.

There 7 full posts and 2 half posts up against the wall. As long as I can do most of the slotting with a power tool it won't be too bad to finish off under the shoe rails by hand. I may be making a bigger deal of of this than it actually is.

Thanks,
BH Davis

6/8/21       #15: Low profile slotter ...
Craig Caughlan Member

Website: http://click design.com.mx

A little late with this post to be of much help, but still...A trim router with an offset base sounds good, although I've doubts you can find a 1/16" straight bit with flutes 3/8" long. Even so, you would have to make multiple passes to keep it from breaking. I've been having terrible luck with Amana bits breaking on a shallow first pass from 3/32" bits to 1/4" in pine. Amana being the brand that is available in Mexico without spending exhorbitant shipping costs importing a Whiteside.


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