I see what you mean I was thinking the dowels could be quite long and go almost all the way through the block, i think it would be stiff enuf then if I used large dowels. It doesn't need ultra high accuracy anything less than 1mm would be very nice. I'm kinda hoping the method I find i can do with out having to change cutters which is a huge 5"x 1 1/4 bullnose or spend too long having to machine things to set up. I think we are on the right lines though