Darryl Keil Last Activity 2025-09-09 11:09 AM
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Paul Kierstead

Posts: 39

Joined: 2008-01-24
Location: Ottawa, ON

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Subject : Dealing with those funny sized (thickness) panels.
Posted : 2008-10-09 12:56 AM
Post #34986
I am build a bunch of frame-and-panels. Later, it will be quite a bit more then a bunch, so a reasonably efficient approach is good. I've done this with raised panels before, but here the panels will be veneered flat panels.

I'd like to make the frames somewhat traditionally. Before, I would do something like run a 1/4 groove down the rails/stiles, use a hollow chisel mortiser with 1/4" bit and poke out the mortises, the cut haunched tenons to fill the groove and mortise. But, these odd-size veneered panels (no way I'm going to end up with nice even 1/4" thick panels) wreak havoc; sure I can cut the groove to fit (though am almost tempted to get a custom router bit for this...), but the mortises will be a real PITA. I don't look forward to using a router for the mortises, and the hollow chisel mortiser is bad at arbitrary sized mortises. I could make the groove one size and the mortise "standard" (the groove will almost certainly be over 1/4", but this makes the haunch a serious PITA, since it would be a different size then the tenon.

How do you deal with this?


 
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Brad

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Joined: 2008-04-22

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Subject : RE: Dealing with those funny sized (thickness) panels.
Posted : 2008-10-09 3:05 AM
Post #34987 - In reply to #34986
This is an interesting Q. I will be curious to hear the replies. I was contemplating this for my passage doors. I used a 3/4" mortise, but that left me a 1/32" gap (each side if I recall correctly) for my panels which is a bit more than I like. I thought about undersizing the panel groove, but that would mean a bit more paring of the haunch and stubs than I like. Another option I thought about was an applied moulding, but that seems like a bit extra.

What is the width of your rails/stiles? Must be pretty big if you are mortising them. If they were small I would wonder if just a stub tenon would suffice? Then you could make the groove custom to what ever you need.

Brad


 
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Darryl Keil

Posts: 1455

Joined: 2003-05-22
Location: Maine

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Subject : RE: Dealing with those funny sized (thickness) panels.
Posted : 2008-10-10 7:59 AM
Post #34988 - In reply to #34986
Paul,

I dont know if this simple solution is acceptable to you but why not just rabbet the panel on the back side so it will fit cleanly into your 1/4" groove? This is what I do under the circumstances.

Darryl Keil


 
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BigRob777

Posts: 142

Joined: 2008-05-26
Location: Newark, DE

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Subject : RE: Dealing with those funny sized (thickness) panels.
Posted : 2008-10-10 10:21 AM
Post #34989 - In reply to #34988
That's what I would do. Even if it is seen, if you darken the rabbet, it won't really show.
Rob


 
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Paul Kierstead

Posts: 39

Joined: 2008-01-24
Location: Ottawa, ON

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Subject : RE: Dealing with those funny sized (thickness) panels.
Posted : 2008-10-10 3:37 PM
Post #34990 - In reply to #34988
Thanks for the ideas! I am not comfortable with a stub tenon; plus, it doesn't meet ... intent? (I don't know how to describe it) for this project. I will admit I hadn't really thought of it, though It is a good idea.

The rebate one I kind of thought of, but I thought of an equal rebate (front and back) which was a bit of a mental block I think. I have a couple of initial panels where the back is entirely hidden, so I will try it on those and see what it looks like. The only real problems will be getting a very even rebate and making it look right; in this case, the depth of the rebate is likely to be extremely shallow, which visually might be odd. Maybe if I went metric on the groove/mortise, got that rebate slightly deeper.... well, in any case, it is worth a try, being essentially free since a screw up isn't visible... (on the first two anyway...)


 
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Darryl Keil

Posts: 1455

Joined: 2003-05-22
Location: Maine

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Subject : RE: Dealing with those funny sized (thickness) panels.
Posted : 2008-10-10 9:27 PM
Post #34991 - In reply to #34990
Paul,

Another option is to get someone with a wide belt sander and reduce the thickness of your 1/4" panel until, with veneer, it comes out the thickness of your groove.

Darryl Keil


 
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Paul Kierstead

Posts: 39

Joined: 2008-01-24
Location: Ottawa, ON

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Subject : RE: Dealing with those funny sized (thickness) panels.
Posted : 2008-10-16 2:55 PM
Post #34994 - In reply to #34991
Well, in this case it turns out the panels are remarkably close to 5/16". So I plowed out the groove to 5/16" and cut in the mortise at 1/4" and pared out to 5/16". Made tenons 5/16". Works well. Now that those two panels worked out nicely, I'll get a 5/16" router bit for the grooves and a 5/16" hollow chisel bit, it will go quick for the remaining ones.
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