Awesome doors, I hope to build something as nice one day. One question: Did you consider using a series of Dominoes to connect the rails and stiles together instead of using a large mortise and tenon?
I've built a traditional frame and panel door before, and have to admit if I did it again, I would be tempted to use Dominoes, but wonder how many to use and whether they would be deep enough for such a large door.
I do use dominoes for doors but not the Festool manufactured dominoes. I make my own to fit the largest and deepest mortise the domi can make. I have a preference for making my own dominoes, they slip right in and the alignment is perfect. I believe that the festool dominos are too tight not allowing enough room for a strong glue joint. IMO that is why the published joint strength tests rated the domino so weak. I mean the dowel joints were stronger, something was definately wrong there.
I used my home made domino tenons to put together all of the rabbetted doors (glass) but did not document the use in this thread. I wanted to test out and document the operation of the OF-HF/1400 in making large mortise and tenon joints but I think my dominoes would have been just fine. and plenty strong enough for these doors. I have built larger doors with dominoes and they have held up great. You have to remember that there are four joints in a single panel door that reinforce each other. And when building a door with more panels there are even more joints in the frame.
In the future I plan to test out a lock mortiser for making the large mortises. Man talk about fast. I will test it with the virutex mortiser because it can be used horizontally and has dust extraction. Anyone want to send me a virutex lock mortiser?