Frame and panel cabinet door with polycarbonate

[Adam Levitt]

I have a bunch of polycarbonate left over from a previous project. I want to use it as the panels for frame and panel cabinet doors. The poly is 4mm thick. My question is should I make the slot for the panel 4mm wide while making the tongue and grooves for the rails and stiles bigger? Or would 4mm be enough for the t and g? My thinking is this is a bit thin, but maybe enough on a 16mm frame?

[Peter Quinn]

I would treat the polycarbonate as a glass panel and secure it post frame construction from the back like a glass panel with stops. I would make the rail tongues the regular thickness, around 1/4", city of the back of the sticking on the rails pre glue up and I usually make stop cuts on the stiles to get the back of the sticking off before glue up but clean out the corners later.

[Jim Becker]

I agree with Peter.