I just recieved and tried out my brand new rail and stile bit from freud (99-260). I bought it to help make a new set of kitchen cabinet doors. They worked great and the fit on my first trial door is nearly perfect. I had, however, wanted to use a 1/4 inch cherry plywood for a flat panel and the slot that is cut is a full 1/4 inch. The plywood is very loose and floaty in the slot. I am worried about gaps showing and rattling etc.
Just wondering if any one had any brilliant solutions or knew of a rail and stile bit that was sized for plywood. I haven’t glued up the door yet and was thinking about buying some of those rubber or foam spacer and was wondering if anyone had any opinions about them. Or if I would have to use raised panels with those bits to be happy.
Thanks for any help. Brian
Replies
Brian, there is a world wide conspiracy to make plywood that won't fit any router bits. Maybe it's vice versa! They make straight bits in "plywood size" but they seldom fit either. With raised panels, you can make the edge any thickness you want. With flat panels many of us pin them from the back. You can also wedge them, glue in strips, set them in goo or glue, use a stepped molding.
Having the panels loose can be a benefit if you haven't stained and finished them before assembly. You can slide them around to clean up in corners and fix them in place afterwards. Plywood isn't going to move around like solid wood. Expansion and contraction will be limited to the rails and stiles. Pin nailers with 1/2" pins are pretty nice for this. You can toenail them into the groove and they don't show. Gluing in a matchstick size wedge here and there will do the same. Spaceballs, foam or tubing won't keep the panel pressed to the front of the frame.
Beat it to fit / Paint it to match
Brian:
Matching so called 1/4 plywood to the slots your bits are cutting will never work without a lot of fussing with small shims, wedges or what have you. Space balls don't really help - I know, I've tried. True confession: I made the same mistake you did when you ordered your set.
Several manufacturers, including Freud (I think) make stile and rail sets sized for modern plywood. Perhaps you could just get an undersized cutter to replace the one that came with your set.
That said, I've not been real happy with the fit of the plywood in a dedicated plywood set either....the plywood seems to vary from maker to maker or from batch to batch.
I haven't completely solved this problem yet myself. I am considering trying to make solid 1/4 panels the next time I make doors - hopefully the project will be small, both in terms of number and size of doors!
Good luck! Maybe some other Knotheads will have different tips/solutions. I'll be watching.
Brian,
I've been buying Cherry veneered to a MDF core that finishes to a true 1/4" through my local supplier. If anything, it fits my bit set a little tight. It may be worth looking around some.
Good luck,
Matt
http://www.oldgreenwoodworking.com
One solution for this problem is to use a matched stile and rail set from http://www.eagleamerica.com and also order the flat panel conversion kit (part # 100-8520) they are designed to cut a 5.5mm(7/32) slot and a larger cutter for the cope cut. I still recommend space ball for lateral movement. Freud may have such a set of slot cutters to fit your S/R bits but I'am not sure.
Work Safe, Count to 10 when your done for the day !!
Bruce S.
Thanks for everyone's help. I just ordered the 1/4 inch MDF cherry and hopefully that will fit better. If not I may try a new bit or use my pinner. Thanks again
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