Step 1: Cut a Triangle

Cut the 3/4" plywood, which is about 2' wide and longer than the table saw's fence, into a long triangle. The angles of the triangle depend on the angle at which you want to send the work piece through the table saw. The wider the angle, the wider the flute width.

Step 2: Cut a Strip of Wood

Cut a strip of wood the same length as the side of the triangle closest to the table-saw blade. The strip should be 1-1/2" wide and 3/4" thick. Using screws, attach a 3" x 3/4" x 3/4" strip of wood perpendicular to the first strip. These two strips will act as a spacer between flutes. Mount them on the side of the triangle closest to the table-saw blade.

Step 3: Make a Pass Through the Saw

Set the blade at 1/8".

Make one pass, slowly pushing through the right side of the length of the wood and using the jig as a fence to guide the cutting.

Step 4: Make a Second Pass

Flip the wood to the left side, and make a second pass through the saw.

Remove the spacer from the jig.

Step 5: Complete the Panel

Send the right and left sides of the wood through the saw. Use the jig to guide the cut, but don't use the spacer on these third and fourth cuts.

If necessary, make two more passes with the spacer, followed by two more passes without the spacer. Continue making passes and removing spacers until you've completed the panel.

Sand the inside of the grooves with low-grit sandpaper.