Thank you all for the help, Still looking for a better (safer) way of
doing this. Problem is that the mullions are not flat overlays but true
mullions that get profiled on both sides. the sticks start out as 3/4 x
1 x 24" . One of those times when a picture is worth a thousand words I
guess ! One side resembles a tongue so if I cut that first on a large
board and harvest it I can then rabbit a same thickness board, insert
the mullion and then route the face side. Maybe hot glue in a couple
spots would hold it temporally. Thanks again folks, will let you know
what works ASAP.
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