You have it pretty well down. I do have some extra parts I cut and can post some pics of those later... that will hint at the process... don't mean to be so cryptic.:shifty:Thats not easy to do without a thickness sander of some kind. Did you make a new purchase you would like to share with us?
No special sander... just tight tolerances.:blink:
You are going to post the set up pics sooner or later so lets just cut to the chase.
I was in a hurry and took no process pics this time.:no:
I would do that with a box joint set up with the miter gauge on the table saw. An auxiliary fence on the gauge, cut the half lap dado depth trough the fence, move the fence over the spacing amount and place a stick in the dado on the fence the same dimension as the dado.
Take your wide stock and cut a dado, move it on top of the stick protruding from the fence, cut again and again and again.
Rip and size the sticks to fit the dado.
Something like that?
Why do we have to play this game Bass? You could just post all your pics the first time.:laughing: