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
Step 4.4. Notching the muntin bars
I cut all the ¾” x ¾” (18mm x 18mm) cedar muntin bars to length.
42 pieces @ 21 5/8″ (540mm) long and 24 pieces @ 59¼” (1480mm) long, enough to make 6 grids – two for each door and window unit.
The muntin bars needed to be notched (channelled out) at various intervals so that the notches in the vertical muntin bars would slot into the notches in the horizontal muntin bars and form a rectangular grid approximately 21 5/8″ (540mm) x 59¼” (1480mm).
The notches needed to be the width of a muntin bar and 50% of the depth.
I lay groups of muntin bars side by side.
I marked where to cut the notches along the muntin bars.
The vertical muntin bars needed seven notches spread evenly along the length.
The horizontal muntin bars needed four notches spread evenly along the length.
I then set the blade on my circular power saw to a depth of 50% the thickness of a muntin bar.
I made multiple saw cuts along each of the marked areas and then cleaned the notches out with a sharp chisel.
By doing this I was able to notch out multiple muntin bars at one time.