Popular Tools' flagship 8-inch dado set — 40-tooth outside blades, 8-tooth full-body chippers, 5/8" bore. The DA840 is the standard configuration for cabinet shops and serious woodworkers running 8" table saws. Designed for furniture-grade flat-bottom dadoes, grooves, rabbets, and tenons in solid wood, plywood, MDF, and melamine.
What's included
- 2 × 8" outside blades — 40 teeth each, matched right-hand and left-hand pair, 20° positive hook
- Multiple 8-tooth full-body chippers in 1/8" and 1/16" kerfs for a total stack width up to 13/16"
- Shim set
- Wooden storage case
Why Popular Tools chippers
Popular Tools chippers feature laser-cut bodies that remove nearly half the steel from the chipper plate. Reduced rotational mass means faster spin-up, less vibration on the arbor, easier startup, and quieter operation under load — without compromising carbide tip strength or chipper structural integrity. It's a small detail you'll feel every time the saw comes up to speed.
Specifications
- Diameter: 8"
- Outside teeth: 40
- Chipper teeth: 8 per chipper
- Hook angle: 20° positive
- Bore: 5/8"
- Maximum stack width: 13/16"
- SKU: DA840
Best for
Cabinet construction, drawer-slide channels, shelf dadoes for plywood and melamine, rabbets and tenons, half-laps, and box joints in hardwood, softwood, plywood, MDF, and melamine. The 40-tooth pattern with matched right/left-hand outside blades leaves clean shoulders even in cross-grain cuts.
Other configurations
- Same set in 1" bore: DA840G — for 8" saws with 1" arbor
- Negative-hook version for radial arm / SCMS / melamine: DA840N
- Wider 24-tooth version for faster production cuts: DA824
Custom bore, pinhole, or keyway? Modified in-house.
Popular Tools operates a full machine shop with wire EDM, precision lathes, and mills. They can bore the center hole to a custom arbor size, add pinhole drive patterns, cut keyways, or split blades for specialized mounting.
- Ships in 1-3 business days from the Popular Tools machine shop
- Rush option: $30 per blade for priority handling
- Tight tolerances and minimal runout
Learn more → or call (855) 628-7297 for a quote.
Compatibility
- Minimum 1-1/2 HP table saw with dado capability
- 5/8" arbor
- ⚠ NOT compatible with SawStop table saws. SawStop maintains an approved dado list — buy from that list if you own a SawStop.
Setup & safety
- Outside saws always mount on the outside of the stack, chippers between them
- Never run chippers without both outside saws installed
- Confirm rotation direction on every piece before tightening
- For deep dadoes or low-power saws, make multiple progressively deeper passes
- Make a test cut in scrap to verify width before cutting workpieces
- Follow OSHA guidelines, wear eye protection, keep hands clear of rotating tools
Frequently asked questions
Will this work with my SawStop?
No. This dado set is not compatible with SawStop table saws.
What's the widest cut I can make in one pass?
13/16" with all chippers stacked. Use shims to fine-tune between increments.
Do I need the 3/32" chipper?
The DA840 ships with 1/8" and 1/16" chippers, giving you most common cut widths. If you need a 3/32" chipper for additional width options, order one separately (CFP88332).
Can I cut undersized plywood?
Yes — use shims and the included chipper combinations to dial in 15/32" or 23/32" widths for undersized 1/2" and 3/4" plywood sheets.
Can the blades be re-sharpened?
Yes. Standard carbide-tip sharpening — most local sharpening services can handle it.
