Dimensional Accuracy in MDF vs Various Milling Combinations

What the heck does that title mean? I’m working on a project where I’m routing some MDF on a ShopBot. To help me get some good angles and built in guides for assembly, I decide to add an edge relief for a 90 degree joint. Basically, I milled out a 1/8″ deep recess for some 1/2″ MDF to sit in. Here’s a picture to explain it:


A vertical piece of MDF sits in that recess to create a 90 degree joint.

The problem is that when I put the pieces together, I had a very small overhang, pictured here. That grey piece should be flush with no line.


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