I'm working on a Tall Cabinet with pigeon holes and I'm using the Wine Rack Trellis subassembly.

My product is entirely 1" thick MDF. But when I change the Wine Rack material to 1" thick, 2 things happen. 

1) I get a "Lap Joint" cutout instead of the normal cutout...which doesn't work at all.

2) I get a gap on some of my divisions at the top/sides. It seems to be reducing the size too much, but only on some of the parts.