Face frame help

[jmoo]

I am making a cabinet and I am working on a door right now.  I am basically building this like a face frame and then will add hinges.  I will be using walnut that is 3/4" think and about 2 1/4" wide. 

My question is how do I add a rabbit for the glass panel and use pocket hole to fasten together?  Do I drill the pocket holes first and then add the rabbit?  Or do I cut the rabbit and then the pocket holes?

I do not want to ruin the rabbit or will this be ok to drill the pocket hole after cutting the rabbit.  The rabbit will not be that wide.  Just enough to support the glass panel.

I will center the pocket hole on the 2 1/2" wide piece but I am concerned about messing up the piece when I start this.

I am hoping that someone has done this before and can pass along some pointers and suggestions.

 

Thanks

[Jay Boutwell]

Jmoo, Build the door first and cut the rabbit with a router and a bearing guided rabbit bit. Square the rounded areas in the corners left by the guided bit up with a chisel.  When you bore the holes for the pocket screw keep the inter holes  1 inch away from the edge.  I would use either a bit that cuts a 3/8 or 1/2 inch wide rabbit. 

If you cut a rabbit with a table saw you will have to make stopped rabbit cuts which will mean accurate plunge cuts and then accurate lifting of the  material from the saw blade on the two stiles.  Otherwise you will have to deal with making plugs to conceal the open groove made by the table saw blade.  You will also have to do some accurate chisel work as the blade being round will not cut up to the intended rail to stile intersection   You will have the glass relief cuts extending past that of the rail intersection unless you make these joints using 45 degree miters.  By using the router rabbit bit method you will not have these as the router bit will follow the inside of the door frame.  once cut you can measure and cut the glass to fit the opening and the easiest method is secure the galss into the frame is use a clear silicone. 

I spoke about the mitered joints above and this is another method of making the joint without having to make the controlled table saw cuts.  If I was doing this I would use a router and bit method and I would not use pocket screws either but would go for the spline joint or a mortise and tennon to avoid the pocket holes.  If I had to complete this project using only a table saw I would definately use the miter joint with splines or mortiose tennon. 

[jmoo]

Thanks.  Those are some great suggestions

[Jens Jensen]

JMOO  That post by Jay ,you should go to the bank with his answer. Jay has been building cabinets longer than some people on here are old   ,,Just kidding !!!  What he says should be the gospel