Panel thickness question

[jussi]

I decided to do flat panel doors for a set of kitchen cabinets. The stock I have is just over 5/8" thick (after jointing and planing). I plan on using a rail and stile router set and I believe the groove it makes is 3/8" (maybe 1/4"). Is there any downside to just rabbeting the the panel stock to fit the groove instead of planing everything down to the groove thickness?

2nd how wide of a rabbet (with respect to the groove) should I make the rabbet for expansion. I believe the groove is 3/8" deep. Should I make the rabbets 1/2", 5/8", etc wide?

3rd I'm using space balls. When sizing the panels how much do you allow for the compression of them. If say they were 1/4" in diameter (I don't recall the exact size) do make the panel exactly 1/2" smaller than full width ?

[JGrout]

spaceballs: with solid wood panels under 24" wide I make the panel 5/16" narrower than the total width of the rails when measured stub tenon to stub tenon.

Rabbeting the stock is fine. I prefer to rabbet and bevel the raised section but either works. I generally make the rabbet 1/2" to the edge for movement in 3/8" deep grooves

On the back if you want the protrusion to be less move the grooves to the front a bit more than say the center of the rail and stile stock

Joe

[jussi]

Thanks joe. Do you do the rabbet and bevel on the tablesaw or router table?

[JGrout]

yes...

in your case I would suggest the TS first so you can see if the results are acceptable.

if not remove most of the waste in the TS and clean them up on a Router table

[MichaelMouse]

JGrout said:

---

spaceballs: with solid wood panels under 24" wide I make the panel 5/16" narrower than the total width of the rails when measured stub tenon to stub tenon.

Joe

---

Screen spline. http://www.lowes.com/Windows/Window-Scre...0zvkc/pl#!

[JGrout]

MichaelMouse said:

---

[blockquote]JGrout said:

---

spaceballs: with solid wood panels under 24" wide I make the panel 5/16" narrower than the total width of the rails when measured stub tenon to stub tenon.

Joe

---

Screen spline. http://www.lowes.com/Windows/Window-Scre...0zvkc/pl#!

---

[/blockquote]

odd I could have sworn the OP asked about spaceballs.

[MichaelMouse]

JGrout said:

---

[blockquote]MichaelMouse said:

---

[blockquote]JGrout said:

---

spaceballs: with solid wood panels under 24" wide I make the panel 5/16" narrower than the total width of the rails when measured stub tenon to stub tenon.

Joe

---

Screen spline. http://www.lowes.com/Windows/Window-Scre...0zvkc/pl#!

---

[/blockquote]

odd I could have sworn the OP asked about spaceballs.

---

[/blockquote]

Recommendations. What a forum is for. Easy, inexpensive, instantly available items that do the same job should always be considered. Snobbery has a price.

[JGrout]

Quote:

---

Snobbery has a price.

---

so does substandard materials

spline linked is flat making it inappropriate for the application

[rwe2156]

You fit the panel according to how you expect wood to expand or contract after assembly.

If expand you can make the rabbet edge about 1/16" wider (7/16 to 1/2) or if contract just make them tight. Leave the lip on the backside of the door. 3/8 is a rather wide groove 1/4 is adequate.

I've never seen the need for spaceballs. If you finish the panel before installation you need not worry about uneven wood movement.

If you're relying on them to eliminate chatter, that is a function of how tight they fit in the groove they won't help with that.

[ruffcutt]