Most people make this *much* harder than it needs to be. If you measure the
stub tennon length of your rails that the cope cutter makes, what is the
length? My CMT set is 7/16, make your rail and stile stock 2" plus the stub
Since my CMT set copes 7/16", I make all my rail and stile stock 2-7/16".
This makes the math dead easy. For a 10" wide, 20" tall door, my rails are
6" and my stiles are 20", the panel is 5"-15/16 x 15-15/16". Since you added
the stub tennon length to your rail and stile stock, you simply subtract 4"
from the overall width of your door to figure out the rail length. The panel
size is the overall door size minus 2-1/16" in both directions.
I find I don't need a calculator when I used this method.
If I didn't explain it well enough, let me know and I will try again.
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