Hi @usagrown. I recently started down the same road of working on the dovetail boxes. I’m new to the craft, so this seemed like a good place to start after I finished my bench. I have the same problem, but I happened upon this article on resawing by hand from a trusted source of hand-toolery. My first attempt was a little rough, but that was on a practice piece. I was able to re-dimension stock down from 3/4 to 1/2 for the sides and a little under 3/8 (maybe 5/16?) for the bottom of the tray using Bill Pavlak’s hand resawing method. Hope this helps if you’re still giving it a go.
For clarity, the only stupid question is the one not asked! I have all too often developed routines to accomplish a given task only to be shocked when presented with a method used by another woodworker that is often simpler and quicker but yielding similar results. I invariably ask myself, “Why didn’t I think of that?” Our friend, Paul, has caused me many moments like that! LOL
I realize that this is an old thread, so my apologies, but some thoughts on resewing:
If you start with your typical 3/4″ thick board and resaw it to get two boards, you will most likely end up with both boards being about 1/4″ thick by the time you’re done. Whether you use a rip saw or a band saw, you’ll need to take into account the saw kerf, which is going to be substantial given the type of saw or saw blade you need; any wandering on the cut, which is a possibility given the amount of cutting you have to do; and the flattening and smoothing of the rough surface that results. And don’t be surprised if the re-sawn board cups, bows, and twists all over the place, especially if it’s kiln dried wood from the home center.
If you need a 3/8″ board, you could make the cut line at slightly proud of 1/2″; your off cut will be very thin, but you still may be able to find a use for it.
If the amount you need to remove is 1/4″ or less, you’ll normally be better off with planing it away.
Resewing is most useful when starting with 5/4 or thicker stock and you want to get two thinner boards. And, if you’re going to resaw, start with something like pine to practice on. It has its own challenges, even when using a bandsaw. It’s best not to use hard maple as your practice board; DAMHIKT.
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