I just finished building and installing kitchen and bathroom cabinets. I'm looking to build about 60 full overlay Shaker style doors and drawer fronts, all square profile and painted white. The rails & stiles are 2 1/2" wide with the stiles the full length of the fronts. The center panel will be 1/2" Baltic Birch. I want to rabbet out the plywood to leave a 1/4" tongue to fit into the rails & stiles. The plywood will be flush, on the back of the door and recessed back from the face of the rails & stiles. I don't want the edge of the door frame to show a cope & stick profile. Would rather do a mortise/tenon joint. But How?
The rails can be cut the full length and the plywood just notched out, so I should be ok there. How would I start and stop the groove in the stiles and also cut out the mortise, while on a router table. I was hoping there would be a bit, like half of a T&G set, that I could use and 'plunge' horizontally the stile to cut the groove. Will I have to take the stiles off the table to make the mortise? Any suggestions are appreciated.