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Window Sash Set

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Steps 5 - 7

Steps 5 - 7

5 Complete the tenon cuts on the rails by placing them outside edge down on the tablesaw. Make multiple cuts with the dado set 5/8" high as before.

6 Install the coping bit in your router table. Place the face side of a rail on the table and adjust the coping bit up so the tops of its cutters contact the tenon. With the fence adjusted so the coping bit cuts 1/4" past the tenon shoulder, cut both ends of the rails, sash bar, and muntins. (For a 1-1/4"-long tenon, set the fence 1-1/2" from the cutter tip with the tip rotated to its farthest distance from the fence.)


7 Mark the positions of the mortises on the stiles by using the tenon that mates with it. First, as shown above left, stand the stile inside edge up on a work surface, and position the rail to mark the length of the mortise. Then, rest the rail on top of the stile, as shown above right, to mark the mortise width. Use the same steps to mark the position of the mortises that hold the sash bar and muntin tenons.

Cut the mortises 3/8" deeper than the length of the tenons. The mortise in the sash bar will go completely through it.

Continued on page 4:  Steps 8 - 12


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