Window Sash Set
8 Install the profile bit in your router table, and adjust it as shown above. With the face side down, mold the inside edges of the rails and stiles.
9 To perform the same operation on the sash bar and muntins, clamp a secondary fence onto the router table, as shown at left. Make this fence from 1-1/4"-thick stock, and position it so the sash bar and muntins slide snugly between it and the main fence.
10 Mold both edges of the sash bar and muntins. Use pushsticks to pass the stock between the fences.
Use a fine-toothed saw to remove the small amount of material on the outside end of each stile mortise, as shown in the illustration at left and in the Stile Detail drawing (page 1). If you make more than one window or door you may want to set up a router table with a straight bit to do this more quickly.
Now's a good time to trim the muntin tenons that intersect the sash bar. Cut them to 1/8" long.
11 Assemble the project without glue to check for fit and squareness. Disassemble, apply glue to all mating surfaces, and clamp. Check for square again before the glue sets up.
12 Install the glass in the rabbeted openings on the back face of the door or window. Each pane should be 1/8" smaller in width and length than the rabbeted opening it fits into. Mount the glass in place with glazing points and glazing putty, or with quarter-round strips of wood mitered on their ends and nailed down (see the Glass Stop Detail drawing - page 1).
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