I want to use a cleat and a pair of corbels to attach a mantel to a brick fireplace. The mantel is 3.5" thick, 68" long, and projects out 8".

I'm thinking the cleat will will be 1.5" thick, will project out 3", and will run 50" long.

I want to cut a slot that runs 1.5" wide by 3" deep, centered into the back of the solid 3.5" thick cedar mantel, so that the mantel fits over the cleat.

My circular saw will cut 2.5" deep; so I can notch-out a 2.5"-deep slot, which might work. But I'd like to go to 3". What's the best way to cut that slot into the back of the mantel? Any ideas would be much appreciated.

This message has been edited. Last edited by: IndianaGuy,

One obvious way would be to get a saw with a larger blade. You could do it on a table saw, although making the plunge cut to start is just a little tricky.

You are making a lot of work for that extra 1/2". Actually, an extra 5/8" as most circ saws go to 2-3/8" depth. I would just make the notch to the max depth that you can do with your saw, then size your cleat accordingly. That extra 1/2" or so is just not going to give you that much to warrant the extra effort.

Actually with corbels you could get by with a 3/4" cleat. Like Jaybee stated you will not gain that much in the additional depth.

you could drill holes in the corners, and make four hole-to-hole cuts with the saw, blade set at 5/8 or so.

I think I'll just go with the 2-3/8". I'm sure you're right. With the korbels, it'll be fine. (Just need to keep my grandson from hanging on it!)