Table of Contents
- 2The size of the thing
- 3About the measurements used
- 4A visual index
- 5Overview of the head
- 6Step 1.1. The head side-frames.
- 7Step 1.2. The head inner support structure.
- 8Step 1.3. The form (mold) for the hypertufa.
- 9Step 1.4. Hypertufa
- 10Placing the hypertufa
- 11Hypertufa - The curing process
- 12Step 1.5. Slurry
- 13Off with the formwork
- 14Step 1.6. The head side-covers and the crown
- 15The crown
- 16Fixing the trim to the side-covers
- 17Step 1.7. Fiberglass
- 18Step 1.8. Paint - undercoating the head
- 19Overview of the body frame
- 20Step 2.1. Shaping the frame members
- 21Step 2.2. Cutting the frame members to length
- 22Step 2.3. Making the wall frames
- 23Step 2.4. The body frame
- 24Step 2.5. The shackles
- 25Overview of the Neck
- 26Step 3.1. The neck - making the box unit
- 27Step 3.2. The aluminum angle for the sign
- 28Step 3.3. Internal perimeter pieces
- 29Step 3.4. Fitting the neck
- 30Step 3.5. The telephone sign
- 31Step 4.1. The trim around the door and window openings
- 32Door and window overview and plan
- 33Step 4.2. Wood for the door and windows
- 34Step 4.3. Joining the stiles and rails
- 35Step 4.4. Notching the muntin bars
- 36Step 4.5. Fixing the muntin bars
- 37Step 4.6. Painting the door and windows
- 38Step 4.7. The acrylic sheet
- 39Step 5.1. Making the base
- 40Step 5.2. Some painting
- 41Step 6.1. Putting it all together
- 42Some strengthening and the door closer
- 43The desired effect
- 44Step 7.1. The rose and ceiling
- 45Making the rose pattern
- 46Marking, drilling, and cutting the rose
- 47Tapering the rose
- 48Painting and fitting the ceiling and rose
- 49The light goes on
- 50The plans
Door and window overview and plan
The door and two windows were identical in make although the door was about 5/8″ (15mm) narrower than the windows as it had to have clearance to open and close.
The door/windows were constructed out of 1 1/2″ x 2 5/8″ (65mm x 39mm) cedar for the side stiles (the vertical sides members) and the top rails (the horizontal top member).
The bottom rails were made out 1½” x 7¼” (180mm x 39m) cedar joined together to make the required width.
The muntin bars (grilles, grid) were of 3/4″ x 3/4″ (18mm x18mm) cedar.
There were two grids of muntins per door/window. A sheet of acrylic was sandwiched between the two grids.
Note: If you are making this door or window, use the measurements as a guide only, as the wood that you use may differ in size along with other inconsistencies.
Check all measurements on site.
The imperial measurements given are not an exact match for the metric measurements. Use one or the other but don’t mix and match. For the most part 1″ is translated into 25mm for rounding off purposes. In other words, a telephone box made using the imperial dimensions will be slightly bigger that if you use the metric dimensions. About 1.6% or so. Not really worth worrying about.