DIYbanter - View Single Post

In article ,
says...
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

You can do the roundover and then cope the rails to the stiles. All you
need is a good sharp chisel and a good sharp gouge. The rails need to
be longer by double the width of the profile of the roundover. You
remove the profile on the stiles by the width of the unprofiled portion
of the rail, and then cope to fit. I've made several full-size doors
this way, which is the original way of doing it.

(excuse me if this gets posted twice, btw)

Kim