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Thanks to everyone for the additional suggestions. The best method was based on one suggested by Alf. In the end I worked a small quirk on the face edge to the depth of the rebate. The waste was then chopped out to just short of the finish line with a firmer chisel and a spoon chisel to cope...

Many thanks for the prompt responses. Jacob's idea sound like a good alternative, but unfortunately the leaded lights are already made with the semi-circular heads, so the potential for cheating is eliminated. Ahem, :oops: , during making the stiles a mistake was made with the moulding plane...

Esteemed Galooterati, having been a long-time lurker I now have a sufficiently knotty problem that you may be able to help with. I am currently working on the top rail of a front door that will received leaded light top panels that have semi-circular and shouldered heads. Accordingly I need to...