I found out you can cut almost any size rabbet with a combination of a rabbeting bit and a straight bit. The rabbet bit has a bottom guide and the straight bit has a top guide. On the first gate the panel is held in place by stays on the front and back. On this gate the panel is recessed into a rabbet and will be held in place with stays on the front. The rabbet is cut deep enough so the panel will rest against the rails that are seated in the back with lap joints (see previous blog). I made them about 3/4” wide using a 3/8” bit and a straight bit.
And here’s the first dry fit with the untreated copper panel in the background and the template on the right.
-- tim hill www.newcalshop.com