I routed the bead off the back side of the window opening my new shop door so I could install glass. Then I spent awhile measuring (twice
), cutting to length, routing the profiles, and installing the muntins. Maybe I'm finally getting the better of my impatience- everything fit as it was supposed to. Yippee!!!!
I used the same rail and stile bit set I used on the door to cut the muntins but had to make a carrying jig to hold the muntins firmly and safely while I cut the second side on the router table. To make the jig I used the rail end bit to cut a profile along the side of a long piece of scrap stock. I set the first profiled side of a muntin in the matching profile of the scrap piece to hold it while I cut the second side of the muntin.
I used spacer blocks to ensure proper alignment of the parts during glue up. The muntins on the front side of the door are mainly decorative. They are just glued in place and to each other. They are held well enough but are not structural.
Tomorrow I'll get a piece of laminated safety glass, then make another set of muntins for the back side of the door. This set will be removeable so I can clean or replace the glass.
Nearly completed front side of door:
Another view:
Close-up of muntin intersection:
Close-up of muntin-rail intersection:
I used the same rail and stile bit set I used on the door to cut the muntins but had to make a carrying jig to hold the muntins firmly and safely while I cut the second side on the router table. To make the jig I used the rail end bit to cut a profile along the side of a long piece of scrap stock. I set the first profiled side of a muntin in the matching profile of the scrap piece to hold it while I cut the second side of the muntin.
I used spacer blocks to ensure proper alignment of the parts during glue up. The muntins on the front side of the door are mainly decorative. They are just glued in place and to each other. They are held well enough but are not structural.
Tomorrow I'll get a piece of laminated safety glass, then make another set of muntins for the back side of the door. This set will be removeable so I can clean or replace the glass.
Nearly completed front side of door:
Another view:
Close-up of muntin intersection:
Close-up of muntin-rail intersection:
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