Hey BJ!!!
1st off you have an amazing eye. The tenons / groves where suppose to be 3/8” deep but I forgot to fine tune my fence setting so they end up being about 7/16! But that's why these are prototypes
Back to the hinges. After testing a sample hinge on scrape I realized the standard 35mm Euro hinge is NOT going to work.
These are face frame cases and I wanted the largest overlay possible to make the doors as large as possible. The samples I picked up from Home Depot are 1 3/8” overlay. But like you can see the 1.5” wide rails /stiles are not going to cut it.
Rocker has hinges that use a 26mm cup but not for face frames:
http://www.rockler.com/product.cfm?p...er=26mm%20hing
Ferrari makes them with a 26mm cup but the max overlay is way too small (9/16’):
http://www.ferrariamerica.com/.%5Cpu...Cpdf%5CE71.pdf
I might have to switch to wider stiles / rails to stick with standard hardware. But an issue there is a few doors are VERY narrow. In those cases I guess I would have to just use a solid piece of wood.... Any ideas would be great.