I have 20 cope & stick type cabinet doors in-process, all pieces cut and ready for glue-up. When checking fit in the coped end during setup, I missed seeing a very slight gap of about .010"-.012" between the stile profile cut (it is a cove style profile) and the rail mating surface (bead shaped cope). The gap follows the curved sufaces only. The tenon fit is perfect and the rail & stile top and bottom outside surfaces are perfect.
What to do about the gap? I am concerned that even though the tenon and all other features of the joints are perfect, that I will loose a fair amount of the strength that the joint would otherwise have due to the gap along the curved surfaces. The door panels are 3/4" MDF and the largest door (~20"x27") is kind of heavy. Titebond II or III can probably fill this gap but since this area will not experience clamp pressure during glue-up, strength will be lost.
What about epoxy? and in particular, System Three T-88. I was thinking that epoxy may not need clamp pressure to develop max joint strength, is this correct? And will I end up with an incredible mess?
Any and all thoughts are appreciated.
Thankyou