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How to Cut Cabinet Double Wide Rails and Stiles without Tearout to Save Time
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Cutting two wide rails at one time To reduce tearout and save yourself some time, cut your rails and stiles two at a time with one piece twice the width you need.

When I’m making rails for cabinet doors using my cope-and-stick router bits, I can eliminate tearout from the end-grain cope cuts and work more safely at the same time if I mill two rails from one wide workpiece. Here’s how to do it: Start with a workpiece that’s twice the width of the rails plus about 1/2". Crosscut it to the final rail length. Cope the ends first, then mill the sticking profile along both edges. Rip the workpiece down the middle, and you’ll have two tearout-free rails a little wider than you need. Trim them to final width, or wait to do this until after your doors are glued up and ready for final sizing.

posted on February 1, 2010 by Woodworker's Journal
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