Help: Looking for ideas on how to build a frame for stained glass window

[Ralrick]

Anyone have experience with designing a frame for a 40lb stained glass window that measures 46"x32"? I'll be using material that is 2" thick, the window itself is 7/16" thick and then there is a back light that is 5/16" thick. I was planning to put a full backing on the frame using 1/8" plywood. I'm looking for a frame design and joinery ideas to ensure the frame is stable and can hold the weight. Ideally I could build in a french cleat on the top part of the frame for hanging but that is not a requirement. Anyone have experience with this kind of build that could offer any ideas or sketches for how to make the frame and the joinery for the corners?

Let me know, thanks.
Rick

 

[Canuck]

Anyone have experience with designing a frame for a 40lb stained glass window that measures 46"x32"? I'll be using material that is 2" thick, the window itself is 7/16" thick and then there is a back light that is 5/16" thick. I was planning to put a full backing on the frame using 1/8" plywood. I'm looking for a frame design and joinery ideas to ensure the frame is stable and can hold the weight. Ideally I could build in a french cleat on the top part of the frame for hanging but that is not a requirement. Anyone have experience with this kind of build that could offer any ideas or sketches for how to make the frame and the joinery for the corners?

Let me know, thanks.
Rick

Hi Rick

A few years back, A neighbor asked me to rebuild a portion of an old door from a relatives farm house . It contains a series of stained glass panels. A picture of the completed sash. (They wanted use the finished sash as a wall hanging for their home)

100_4222_00

ncwoodworker.net

For the outside frame, I used a Matched Rail and Stile set from Hvalley Tools

8894 MLCS Window Sash Matched Rail and Stile Two Piece Router Bit Set for 1 Inch to 1-1/2 Inch stock, 1/2" Shank

MLCS Window Sash Router Bit Set is a 2 piece matching set that makes rail and stile window frame or sash.

www.hvalleytools.com

The matched set basically gives cope and stick joinery with an inside window sash profile. (I uploaded several WIP photo's in my media albums here.)

Here is a link to my original post of the build.

Window Sash Rebuild (Updated)

I was asked by a neighborhood friend if I could rebuild a window sash that had been cut out of 1920”s farmhouse entry door in Iowa where they had grown up. They are thinking about using it as a wall hanging for their family room. The plan was to add a matted picture of the farmhouse in the...

ncwoodworker.net

(Note that I used another bit to cut all the mullions supporting the individual pieces of stained glass.)

Wayne