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Cope and Profile Cuts Using Matched 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 matched stile & rail bits.

1. Making the Rail cope cuts:
a. See illustration 1 below, noting that approximately 1/8" of edge (reveal) is showing.
b. Make sample cope cut. When satisfied with sample, be sure the material is FACE DOWN, then make the cope cuts on both ends of the rails

2. Aligning Bit for Profile Cuts (See illustration 2 below):
a. If you are using a single router, change to the profile bit as shown below.
b. Take a piece of the sample cope cut and place it FACE DOWN on the router table. Move the profile bit up or down to align the top of the flat cutter with the tongue of the cope cut as shown at right.

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. Now's a good time to determine the raised panel dimensions, see the section on Sizing Materials & Determining Dimensions for Stile & Rail Doors.