First, I will need a Lumber Run..as none of the Leftovers are either long enough, nor thick enough....

 

We have a Back Door with a window...glass to a double pane single "light"...with an add on plastic grille..one on the inside, one on the outside...and there IS a problem..

Ugly...and this is the outside of the door...inside is fine, other than being also plastic...

Need to clean out all the junk that was slopped in to seal up the gaps...try to save a piece or 2..

Maybe use something like this as a pattern for a replacement made of Ash?   Including..

Maybe do a half lap crossing? 

 

I MIGHT be able to use the Sash Cutter in the Stanley 45 for the frame pieces, and maybe a bead cutter for the bar stock...Would need to rebuild both the inside and the outside to match each other...and figure out the Mitered corners...

 

Apparently, there are a series of screws on the inside, to where the outside connects to the inside like the bread of a Sandwich...

Maybe pick some 5/4 Ash and go from there?  May have to re-bed the glass, as well?

 

Might keep me busy for a few days?

 

 

I do have a supply of 1 x 4s in the shop, that I might resaw to 1/2" thickness, and build a fancy box...something to do until I can make the Lumber Run....

Stay tuned..

 

I'll be interested in how you do those joints. I watched Roy Underhill do some by hand and it tweren't easy. I did some some but used all power tools...even that wasn't  a piece of cake. The ones Roy and I did were on a corner cabinet. I do wish I had seen his show first before i did mine, I would have done them a little differently.

Man, Steven, you ARE a glutton for punishment!

pfft:  the dividers are just for looks, so some duct tape cut in thin strips.......done.

Where are we at on the project?

Lack of lumber, and it is way too COLD right now...save this for Summertime..