Thank you all for the help, Still looking for a better (safer) way of
doing this. Problem is that the mullions are not flat overlays but true
mullions that get profiled on both sides. the sticks start out as 3/4 x
1 x 24" . One of those times when a picture is worth a thousand words I
guess ! One side resembles a tongue so if I cut that first on a large
board and harvest it I can then rabbit a same thickness board, insert
the mullion and then route the face side. Maybe hot glue in a couple
spots would hold it temporally. Thanks again folks, will let you know
what works ASAP.

I would try shaping half or the mullion on each side of a wider board, then
ripping each half off and gluing them together. If painting, the seam will
not show.

"garyhuff" wrote in message
...
Thank you all for the help, Still looking for a better (safer) way of
doing this. Problem is that the mullions are not flat overlays but true
mullions that get profiled on both sides. the sticks start out as 3/4 x
1 x 24" . One of those times when a picture is worth a thousand words I
guess ! One side resembles a tongue so if I cut that first on a large
board and harvest it I can then rabbit a same thickness board, insert
the mullion and then route the face side. Maybe hot glue in a couple
spots would hold it temporally. Thanks again folks, will let you know
what works ASAP.

Right on Jack, that is the best idea I have heard. Thank you (and every
body else) for replying, Great Bunch these sawdust guys !

Jack Casuso wrote:
I would try shaping half or the mullion on each side of a wider board, then
ripping each half off and gluing them together. If painting, the seam will
not show.

"garyhuff" wrote in message
...

Thank you all for the help, Still looking for a better (safer) way of
doing this. Problem is that the mullions are not flat overlays but true
mullions that get profiled on both sides. the sticks start out as 3/4 x
1 x 24" . One of those times when a picture is worth a thousand words I
guess ! One side resembles a tongue so if I cut that first on a large
board and harvest it I can then rabbit a same thickness board, insert
the mullion and then route the face side. Maybe hot glue in a couple
spots would hold it temporally. Thanks again folks, will let you know
what works ASAP.