Thanks Dan for bringing that thread back up.
Jon, I build frameless and ran into similar issues recently. One thing to remember is that unless you subtract your material thickness from the left and right front sides, your side panels will be .75\" too long and protrude past the adjacent cabinets.
I ran into the door reveal issue with a customer a few months ago. I was using Blum 45degree hinges and followed their manual on sizing the door for use with that hinge. So, the door is actually about 6mm narrower than the actual opening. I verified this with their tech dept. From the front, the reveal remains consistent but if the cabinet is lighted, you will see a faint glow around the door. That is where this one customer poopooed all over me. No matter the amount of drawings, explaining geometry could convince them that I had sized the door correctly. (Let me quote the customer, \"Now, I ain't no cabinet maker and don't want to tell you how to do yer job, but you don't know what yer do'in.\"
Anyway, in 7 years, only 2 customers have complained. You can get away with sizing the door to equal the opening and then use the hinge's horizontal adjustment to center the door but it will max it's travel out. The only other recommendation I heard was to glue in a finished strip that was 5mm thick to hide the small gap.
I found the hard way that if you size the door wider than the opening, you will more than likely touch the adjacent doors or not open all the way after the hinge cranks out as you open.
Also note that while in the cabinet door editor, the door doesn't take the correct size until you leave the door editor. So, no matter what reveals you have entered when you place the door, it will be overhanging the sides and will show the incorrect size. Return to Main Screen and it will be correct.
I hope this helps.
Chris