Project - "Making the Grandfather's Clock - Rail and Stile and Raised Panel Making

Beth picks up where she left off last week. The back panel has been glued up. The two raised panels have been inserted in the rail and stile groove. The top panel is a piece of 1/4" veneered plywood. It will be added when the other veneered pieces and the glass are added.
	She pops the rabbet bit back in the router and cuts the top section to receive the veneered panel. All the veneered panels will be finished separately and put in place at the last step.
Having done so many "squaring" of corners last week, Beth takes only a minute or two to square the corners of this window.
	The cabinet scraper quickly removes the little trace of glue squeeze out.
Beth takes a few minutes at the Delta Bench Random Orbital Sander to sand smooth both sides. This is where it helps to have the panels cut precisely. The panel surfaces are aligned with the rail and stile so that this flat sander can smooth both.
	The instructions say to make sure that both assembled sides and front and back have the same widths. Beth puts them next to each other and decides that her units are exactly matched.
The plans call for a tongue and groove set to be used to join the four sides. I would not have thought of this for joining the assembly. I think I would have tried using the locking miter bit — that would have given a joint without a seam showing. Beth and I searched through the plans and found that the "seam" will be covered by a strip of molding. So  this joint makes sense. It is similar to dadoing the pieces on the table saw, except that the tongue automatically matches the groove width producing a tight joint.
	Two grooves will be cut into the length of both sides. The tongue is designed to cut a 1/4" width. The bearing allows a 3/8" depth of cut — much too much for 1/2" stock. The plans explain how to swap the pattern bearing to make a 1/4" cut. Rather than to change bearings, Beth and I decide that we can use the fence to limit this depth.
She installs the groove cutter.
	Beth adjusts the fence so that the cutter depth is 1/4". She has raised the router so that the cutter is 1/8" above the table.    Note, the "sawdust." This is actually white plastic from the fence insert. Beth found that the zero clearance insert cut for the Junior Raised Panel was close enough and could be used for this operation with just a small additional routing.
Beth has clamped a featherboard in place to keep pressure on the side as it is routed.
	With the grooves cut in the sides, Beth now installs the other cutter. This one will be adjusted so that it cuts a tongue that is centered on the 1/2" frame stock.
After having  checked all the inserts, Beth decides that a new one will have to be cut just for this cutter. She marks the profile outline.
	Beth cuts the shape at the bandsaw.