Profile Modeler MDF door corners

[Stuart Douglas]

It has been some time since I was trained on the Profile modeler. I was able to get a setup going and a door cut using an asymmetric tool that I created. It is supposed to match an existing thermoform door, but we are just painting ours to match since it is a one-off. My question is this: In the attached picture, the interior region has "squared corners inside of the cope where the raise meets it. The fillet in the same region, where the quarter round meets the rail and stile face, is still rounded to the radius of the largest tool in the setup. My smallest tool is an 1/8" ballnosed bit, and it did the raised panel corner great. Why did it not come back and get that fillet? Is my setup missing something? Do I need to do the whole profile with my smallest bit? I'm sure there is a simple answer but bumbling around with the settings has not made it apparent to me yet. TIA for some experienced help!

[Stuart Douglas]

Over a hundred looks and no-one seems to know how, or has had the same problem? Hard to believe!

[Forrest Chapman]

What is your largest tool diameter? I would rough with something like a 3/8" end mill and finish with a 1/4" ballnose then cleanup with the 1/8". Also check your mdf door design and make sure the "miter corner" box is checked.

Forrest

[Brad McIntosh]

Sorry Stuart...

I would have to go with Forrest's suggestion. Most of our customers up here in Canada doing similar doors are using Panelmetrix.

[Stuart Douglas]

The mitered corner box is checked. I roughed out with the 1/2 downcut, then 1/4 downcut, then went to our 1/8 ballnose. The fillet is still at the 1/2 diam. but the inside, where the "panel" meets the "stile/rail" is finished with the 1/8 ballnose. This has got me thoroughly flummoxed. I'm sure there is a simple remedy, or an error in my setup, I just can't see it.

[David Giesbrecht]

Way old!! But ran across this while looking for something else. When we have issues with not squaring out the corners it is because we have to set the larger bit to leave stock.