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Discussion Starter · #1 ·
Hello Folks

I'm about to make some doors for a kitchen island, using maple for the rails/stiles and maple ply for the flat panels. Doors will be stained.

Problem I've got is that my rail and stile set (ogee) cuts a 1/4" groove/tenon (not adjustable) and as we know, most plywood is undersized. I can use space balls, but this won't keep the panel from moving in and out due to the undersized thickness of the plywood.

If you've encountered this problem, and overcome it :surprise::grin: I could use some advice. Any suggestions are appreciated.

**Moderators - if this post is in the wrong place, please move it. I wasn't sure where to put it**

Vince
 

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a layer of veneer on the back side...
hand sand to thickness if required....
or use screen spline instead of space balls..
or use backer rod...
 

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Finish all parts before assembly so all visible areas are finished. Stick's veneer suggestion is good. I'd still use spaceballs.
 

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Glue the plywood panel in place since you don’t have to worry about wood movement. Put a toothpick or brad in the gap on the back to push the plywood forward until the glue dries.


In woodworking there is always more then one way to accomplish something.
 

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Glue the plywood panel in place since you don’t have to worry about wood movement. Put a toothpick or brad in the gap on the back to push the plywood forward until the glue dries.


In woodworking there is always more then one way to accomplish something.
the rails and stiles need to move...
 
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By the time you get two or three coats of any finish on, sprayed or brushed, those puppies aren't going to move. But shimming from the back to avoid having a visible hairline gap on the front face makes a lot of sense.
i don't even know how one would go about NOT having the finish bond the components..it's going to get pulled into any abutting surfaces that aren't previously sealed.
That's always a problem with things like doors and doublehung windows.
 

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the rails and stiles need to move...

Now I hate to disagree with stick, but

Space balls are to allow a solid wood raised panel to expand and contract, not the style and rails. Any movement of the relatively narrow 2 1/4 inch style and rails will be minimal, and there is nothing constraining the styles and rails from expanding outward. The rails constrain the styles from expanding inward by being glued between them anyway.


In woodworking there is always more then one way to accomplish something.
 

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Discussion Starter · #10 ·
@Stick486 - screen spline and backer rod are both too thick - the gap between 1/4" groove and 5 or 5.5 mm panel isn't wide enough to accommodate either. Good idea with the veneer.
@DesertRatTom - the finish will be stain and varnish. I plan to finish the panels first for full coverage (in the event of movement) but finishing the rails/stiles before glue-up is a bad idea.
@Terry Q - I like the idea of a toothpick or brad to shim the back
 

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...or...instead of a groove, make it a rebate, then use beading or equivalent to hold the panel in...sort of like making a glass door...

I like the veneer ideer...
 

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@DesertRatTom - the finish will be stain and varnish. I plan to finish the panels first for full coverage (in the event of movement) but finishing the rails/stiles before glue-up is a bad idea.
I stand corrected. I do pre stain fancy, two toned picture frames (with the glue area masked carefully, then apply the final coats after glue up and putting in splines to reinforce the miter joints.
 

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@DesertRatTom - the finish will be stain and varnish. I plan to finish the panels first for full coverage (in the event of movement) but finishing the rails/stiles before glue-up is a bad idea.
I stand corrected. I do pre stain fancy, two toned picture frames (with the glue area masked carefully, then apply the final coats after glue up and putting in splines to reinforce the miter joints. For plain frames, I apply finish after glue up and sanding the whole thing. Mitered corners sometimes need a little sandpaper adjustment to look right.
 

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Now I hate to disagree with stick, but

Space balls are to allow a solid wood raised panel to expand and contract, not the style and rails. Any movement of the relatively narrow 2 1/4 inch style and rails will be minimal, and there is nothing constraining the styles and rails from expanding outward. The rails constrain the styles from expanding inward by being glued between them anyway.


In woodworking there is always more then one way to accomplish something.
correct...
 

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@Stick486 - screen spline and backer rod are both too thick - the gap between 1/4" groove and 5 or 5.5 mm panel isn't wide enough to accommodate either.
Good idea with the veneer.
short pieces of spline used exactly like space balls...
I did forget to mention that the veneer is a 100% installation but done as numerous short pieces...
they don't fall out nor loosen...
 
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Stick,
Please educate me, what is backer rod ?

TIA
Dan
 

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My thought would be to edge the maple plywood with hardwood then machine the edges to fit the groves you have available.

It's been a while since I did any cabinets but best I remember the plywood coming from the big box stores was definitely undersized but the good stuff ($$$$) I was getting from my wood supplier was still 3/4 & 1/2 inch. In any event I have a set (3) of bits specifically made for the undersized stuff, made by Whiteside and they are perfectly sized for door panel grooves. I don't remember the price but I'm too cheap to pay too much for things.
 

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Stick,
Please educate me, what is backer rod ?

TIA
Dan
Foam rope used to seal/close deep gaps and open joints before caulk is applied,.
Foam rope used behind/under caulking so that caulk forms two point adhesion...
two point (both sides of the joint) the allows the caulk to stretch/compress as designed/advertised and still maintain adhesion...
three point (both sides and bottom of the joint) makes for a poor/weak caulk joint that will break adhesion on it's own... wastes caulk too...
the smallest dia rod I'm aware of is ¼''... 100' roll is about 3 bucks...
great stuff for sealing window and door installations... way cheaper, cleaner and easier than spray in foams...
another item that works better than space balls is slices of sill barrier/seal...
 

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Foam rope used to seal/close deep gaps and open joints before caulk is applied,.
Foam rope used behind/under caulking so that caulk forms two point adhesion...
two point (both sides of the joint) the allows the caulk to stretch/compress as designed/advertised and still maintain adhesion...
three point (both sides and bottom of the joint) makes for a poor/weak caulk joint that will break adhesion on it's own... wastes caulk too...
the smallest dia rod I'm aware of is ¼''... 100' roll is about 3 bucks...
great stuff for sealing window and door installations... way cheaper, cleaner and easier than spray in foams...
another item that works better than space balls is slices of sill barrier/seal...
Sill/barrier seal is real handy to have on hand at all times too
 
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