Help please with panel fitting

[George Murphy]

I am trying to make a simple frame-and-panel piece. I have dadoed out the rails and stiles with a 1/2 inch router bit to accept the 1/2 inch birch plywood panels. Or so I thought... It seems the bit is maybe a 32nd or 16th too small for the panel.
So I am looking for the fix that is quick, easy, fast, painless. Whatever.
Do I:
Sand the plywood on the inside edges to fit?
Re-rout all the dadoes?
Rout or cut a thin slit down the center of the edge of the plywood so it can flex in from both sides?
Somehow sand or widen the dadoes?

I suppose sanding the plywood is easiest. I just don't look forward to that mess.

Why does something that should be simple become so hard?

Thanks for any ideas, hints, even criticism.

[Lee Schierer]

The best way is to set up your router and make a second pass taking off a slight amount off of one or both sides of the existing groove.

[George Murphy]

Thanks, Lee. That's what I was afraid of. Oh, well, I guess I can use the practice. :rolleyes:

[Bill Huber]

I will second Lee's reply, that has to be the best way to do it.

The problem you have is why I always make test cuts on things like that.

Good luck.

[George Murphy]

The problem you have is why I always make test cuts on things like that.


That's what stinks. I did a test cut and thought that it fit nice and snug. Apparently, only that particular section fit at all. Doh!

[Jim Kountz]

If at all possible take a very very small cut and make a pass, flip the piece end for end and make another pass. This will perfectly center the groove. If you take it all off one side your groove wont be centered.