Originally Posted by HowlerKarma
We really need to know whether or not these frames are going to be filled and painted. What kind of wood is this, hmmm? That might provide us with a clue. wink Pine or aspen is likely to just be painted, and there we might not care... walnut or some exotic hardwood might be more likely to be used with a translucent finish. The joinery would need to be far more exacting in the latter case.

What sort of saw is being used, anyway? Some Japanese saws produce a very tiny kerf, and are ideal for this sort of work.

Inquiring minds want to know. grin

This is why I assumed a high-quality worker and tools for the problem. A saw with a 1/8" kerf for frame making? LOL.

Even with the best saws, the kerf will be a non-zero number, as will any losses due to sanding, but they will be miniscule. Also miniscule will be offsetting gains from paint/lacquer, and space for the joint itself, because I'm assuming we're not using some form of molecular bonding.