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build a window mullion

Gary Chapman

Gary Chapman

Joined
Mar 3, 2009
Messages
244
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Location
Madison, Indiana
Need help
I am making two doors for a hutch and want to make mullions for them and put glass in the doors and need some instruction help on their construction. Anyone have a website or video on costruction of that. Thanks Gary
 
The easiest method would be to use a single split turning and a single pane. Common with mullions and muntins for double pane glass in doors. If you want two panes, use a split turning of a diameter which allows for a square-edged member down the center to allow panes and interior molding to hold them in place. Or, if you're feeling frisky, a squared member with the other half of your split turning holding the pane down.

Split turnings are done a number of ways, including doublestick tape, paper/glue joints, or even mechanical fasteners in places they won't be seen when done to hold the halves together. Cutting them apart after turning would require some precision jigging and a fairly fine blade. I wouldn't use that method, though you could hold things even with good square ends on a sacrificial board and hot glue some support wedges in strategic spots en route.

For some ideas on how-to, search "split turning." Results like this might help. http://www.shopsmith.com/academy/latheturning/images/F12-62LG.jpg
 
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Were it me, using a bearing-guided router bit, I'd radius the edges of a board that's as thick as the width of the stock you need for the mullion, then rip the radiused edges off the board with enough stock to dado the reverse for the glazing insets that still leaves the original radii in tact. You use the same process to make the muntins that will hold the glazing in the frame, but you rip that strip in half on the band saw so that you have lengths of "1/4 round" stock. Way faster than trying to turn a small diameter rod. Match the router bit's radius to the width you need allowing for the thickness of the glass. Quick and easy even without a router table.

You can also use rail & stile router bit sets in the profile that you want.

mm
 
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