So I got the shaker stile and rail router bit and after playing around with the shims a bit I got them matching great. But the center panel of maple veneer over mdf turns out to be from canada and under sized instead of the standard 1/4". Just wondering if you guys have any idea on making the panel so it doesnt rattle and there isn't a gap. Do you think something like space balls will help keep it tight enough and once the finish is on the gap will go away?
Well, cutbacks are a sign of the times, unfortunately.
Fortunately, this issue is pretty well known and we have a solution. Our Plywood Panel Conversion Kit #296 lets you swap out the Slot Cutter in your Matched Rail and Stile bit to cut the proper size slot for undersized plywood: