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Cope and Profile Cuts Using Stacked Stile & Rail Assemblies

Always make sample cope and profile cuts, beginning with the cope cut since any chip out would be removed when the profile cut is made. Use about 18,000 rpm with stacked stile & rail bits.

1. Making the Rail cope cuts: 

a. See illustration 1 below, noting that the bottom of the flat cutter is about 1/8" above the router table.

b. Make sample cope cuts, allowing approximately 1/8" of edge showing. When satisfied with sample, be sure the material is FACE UP, then make the cope cuts on both ends of the rails

2. Aligning Bit for Profile Cuts (See illustration 2 below): 

a. Raise the cutters as shown at left (approx. 3/8").

b. Take a piece of the sample cope cut and place it FACE DOWN on the router table. Move the bit up or down to align the top of the flat cutter with the top of the tongue of the cope cut as shown at left. 

3. Making the Stile & Rail Profile cuts (See illustration 3 below):

a. Make a sample profile cut. Test the sample profile cut for proper fit to the sample cope cut. Make adjustments as necessary for a flush cope joint fit.

b. When satisfied with the fit, be sure the material is FACE DOWN then make the profile cuts on one edge of each stile and rail.

4. Test Assemble the Stiles and Rails to insure a proper joint fit and that the proper door dimensions have been achieved.

1 piece Stacked Stile & Rail Assembly 1582SSRS
The easy way to make perfect fitting Stiles & Rails using only one bit. No need to switch, reverse, reset your fence, or remove the bit from the router. Simply rout your rails, then raise the bit in your table and rout the stiles. 3/8" depth of cut. Suitable for 5/8" to 7/8" stock. 1/2" Shank only.