Set windw fence so that the bearing surface is just flush with the fence. I split the difference and drilled out the majority of the waste at the drill press with window making router bit set variable drill bit and cleaned out the waste with a couple of chisels. New Tax Break investing vaiable Machines! Virutex Tools. Add to cart The second cut is even easier — just flip the push block over and nest the muntin into the profile in the push block. Dovetail Bits.

I will refer to both the vertical and horizontal bars as muntins. Also to make things easy I will refer to the side of the window with the profile as the front, or face, and the side of the window with the rabbets for the glass as the back. With all pieces cut to size and length, it is time to cut the tenons on the ends of the rails and muntins.

Where that tenon falls depends on the thickness of the material, how deep you want the rabbet for the glass, and how much of a fillet you want on the face of the window. I nibbled away the waste on the face side of my rails. Once the tenons are cut it's time to make the coping cuts. The cope cutter is set up in the router table so that the top of the cutter just brushes the underside of the tenon with the rail face down. With this setting, both rails and all the muntins can be coped.

To feed the pieces through I use a miter gauge to support the workpiece and a backer block to reduce tearout. Using a square can help set the router table fence. With the tenons formed and cope cuts made on Window Making Router Bit Set Youtube the ends of the rails and muntins, it's time to lay out the mortises. A wheel marking gauge is quick to set up to define the width of the mortises.

The tenons itself help locate the length of the mortises. A little measuring is required to locate the mortises for the muntins. I gang both rails and corresponding muntins together and mark all the way across the pieces. This ensures that if I'm slightly off-center, I still get square intersections between pieces. The same goes for the stiles. I use a wheel-style marking gauge to set the distance from the cheek of the tenon to mark out for the corresponding mortises.

Using the tenon to mark the mortise eliminates all the guesswork and insures that the mortises will always be in the right location. I use the tenon itself to lay out the location of the mortise in the stile. When marking the location of the mortises for the muntins, I gang all Sign Making Router Bits Uk Windows 10 the pieces together to ensure that everything aligns and is square when assembled. The mortises can be cut a number of ways. The easiest would be with a hollow chisel mortiser.

The most traditional method would be to use a mortise chisel. I split the difference and drilled out the majority of the waste at the drill press with a drill bit and cleaned out the waste with a couple of chisels. You can also set up a straight bit at the router table and plunge away the waste.

As long as you end up with a straight, clean mortise the method is not important. After the mortises are marked out and drilled, use chisels to remove the waste and clean up the mortises.

After making the stile cut at the router table, notch away the little square of material on the ends of the stiles as marked in the photo below. Removing this material allows the pieces to drop together and the cope to match the profile. I use a backsaw for this, but a sharp chisel will also do the trick. Once the mortises are finished all pieces can be profiled at the router table and the small waste piece removed. Once that's done, the window can be dry-assembled to check the fit of the joints.

Now it is time to make a couple of jigs and fixtures that make the rest of the process of making the window a little easier. Using a piece of scrap wood roughly the same dimension as the window frame and about 8" longer, use the cope cutter to run a cope the length of the scrap piece photo below.

Making a custom push block makes the process of milling the muntins much easier. This same piece will also be used as a fixture later on to hold the muntin while you trim the miter joints where the bars intersect. Now mark the scrap piece so that you can remove the material up to the end of the tenon on the back side of one of your rails. With the material in the middle removed you will have a piece with the reverse profile of the window sash.

When making the push block, the last little bit of material is easily removed at the tablesaw with a flat-top blade or at the router table with a straight bit. This simple block is the key to creating the interlocking joint between the muntins. Now take the remainder and add a hook to one end. This becomes the push block for profiling the muntins.

Without this block the process of profiling these skinny pieces can be tricky at best. Adding a hook to the end completes the push stick and the muntins can be milled with ease. Cart is empty. View cart. Sign In or Register Email Address. Password Forgot your password? Register for a new account. Sign In. Remember me. Down Cut End Mills.

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