Hi eric,

> It does look like if I create a shape in the thickness
> I need, do an inset and then make it deep enough to
> just leave the outline,

You want to use the "Grooved" option within the Inset command to get the kind of flush panel that you're talking about.

When you enable that option, a new "Groove width" field will appear, and you can enter in a distance there - you'll then get a flush panel with a channel of that groove width around it.

- Michael