Brett - your suggestion with the copy paper makes sense?since we're only talking about a fraction of a mm, but how and where do you place/secure the paper when you feed a long workpiece past the cutterhead. Manual feed or power feeder would?simply push that paper along with the workpiece, wouldn't it? My pieces are 3 meters long, so they are not supported all the way and it would be a challenge to keep placing paper under the workpiece as it feeds past the cutterhead. Or do you have a trick here that I am missing?
Imran - you are correct that the simplest solution would be to not use a profile?for the glue joint, but my panels are 3 meters long and 90 cm wide. I cannot feed these through my jointer (AD741) to flatten if the joint shifts and is a tad misaligned after glue up. It would need to be in 3 sections and that still requires 2 more glue lines. You are correct that Dominos would solve this problem and I like dominos and have successfully used dominos for this purpose many times, but with 3 meter lengths I thought a continuous?profile joint would result in a faster assembly and cleaner joint. Btw, in your photo I see you have the Plano system in the background which I can imagine would serve exactly this purpose - aligning glue ups to stay flat? Are you happy with it, I am considering getting it, specifically for this type of job. However, having said that, I also had a project a few months ago where I was building a bread-board type panel and the cross piece that needed the groove was wider than the cast iron. This was the first time I encountered this problem. I tried to cut a groove 40mm deep and the slight angle caused a problem on the final fit.