wrote in message
ups.com...


I've got some sample pieces of 1/4" oak plywood, finished on one side
but it measures 3/16", not 1/4". If I router out a 1/4" slot in the
rails and stiles, won't that be too much looseness for the panel?

Buy a smaller bit, the same width as your panels. Or, cut thin shims and
place them in the slots behind the panels.



Also, the 1/4" plywood seems awful flimsy. Do you think it's thick
enough for the middle insert?

Absolutely, glass is often used and is thinner.




Are there any other ideas? Is there a little bit thicker panel than
1/4" or do I have to go all the way to 1/2"?


You can go 3/8' but it will be slightly thinner, rabbit the edges to fit
the slot.