In article ,
Wade Lippman wrote:


I am making a cabinet door. I cut 4 pieces of 1x3 and routed a 1/4" grove
in them to take a plywood panel. I then routed a 1/4" tongue on the ends of
the short pieces to mate with the grove in the long pieces.

I "intended" on assembling the door and then routing a 1/2" roundover on the
inside and outside edges of the 1x3. I made up a partial sample, and like
how it looks; simple but strong.

Well, it just occurred to me that panel will get in the way of the router
bit and prevent me from doing the inside roundover. And I can't do them
before assembly because they won't fit together properly. And I can't do a
temporary assembly because it will be too flimsy to hold together properly
without glue.

I know there are special router bits for this purpose, but I have already
cut the panel grove, so I am kinda committed.

Any suggestions how to make this work?
In the end I expect I will have to assemble it temporarily and hope for the
best, but hopefully someone will have a better idea.
thanks



Howsabout:
place the pieces together, face down, on a flat surface.
place some scrap blocks, say about 2"x5", on the back
(i.e., the exposed 'top') of the frame, at each corner,
and 'tack' them to both pieces.
turn it over, so the face is up, and clamp the assembly, at
all four corners, to a piece of scrap approximately the
size of the entire door
route all four sides of the inside edge.
dissassemble.
insert center panel, and glue up.
route the outside edge.


If the base construction would be subject to flexing, because the
center panel is missing, then you just need to 'reinforce' it during
the temporary assembly, so it _can't_ flex. As my H.S. shop teacher
was wont to say, "You have to out-think the materials you work with."

Which involves: recognizing, allowing for, and *maintaining*the*upper*hand*
*over* "the inate animosity of inanimate objects".