I need some advice in building a custom curved window sash. The opening is half a circle with a diameter of roughly 2 feet. I’ve read about it being constructed two ways. Either cut small 1/8″ rips of wood and bend them around a template or biscuit wider pieces together and use a pattern and a router. If anyone has any tips or suggestions it would be great. Thanks
Greg – Contractor in Saratoga Springs, NY
Replies
Hey I think you will have better luck over
in Breaktime.
Those are both possible ways. Also "Funny" Plywood
(Has the grain all running in the same direction) will
make 2' radius no problem.
Then again you can just make Kerf cuts on the back side
of the board and probably have no issues. Then you wouldn't
have to use plywood.
Greg
Here are a couple of options I have scaned from a 1947 copy of joinery by W.B. McKay.
Is the sash to operating or fixed, if it is to be operating it must be strong and the joints solid. I don't think biscuts and glue would be enough especally on end grain. Remember that the glass will add a lot of weight.
http://www.holtzheritage.com
Greg seems that my attachments won't go through maybe the file is too large.
They both have the sash rails cut from 2 pieces of stock and joined at the top to each other and at the sides to the verticle stiles with either handrail bolts or hamerhead key tenions.
Either laminating thin stock or sawing solid stock to the proper radius would work. I wouldn't try end-joining with biscuits, tho' well made finger joint might work. I also wouldn't use plywood for this since I assume it's exterior and you'd have a lot of endgrain to suck up water if you use ply.
Your challenge might not be the curves, tho' -- it may be cutting tennons and sticking on the curved piece. That'll take some creative jigging. Also, I've always wondered about where one would get glass to fit a curved window. Have you found a source? Re-using existing?
Mike Hennessy
Pittsburgh, PA
About ten years time ago I had a custom wood window maker make a curved window that was hinged on the bottom and opened inwards. The cost of the unit was about 500 dollars. I would think that it might be cheaper but not as much fun to have somebody like that make one than doing it yourself. I seem to remember the sash was made with sections of wood not bent laminations. Anyway good luck
Troy
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