Who’d have thought a bunch of windows could be so difficult? I’d mocked up a prototype of the 2x 6 pane window frames for each panel way way back before I’d even had the body structure built thinking that this would be an easy thing to do, put aside, & resume. How wrong I was!

I tried a number of designs including mortise and tenon & bridle joints and in the end setttled for the half notches (not actually a join, but a fit). The main reason was ease (relatively speaking) of construction however, the joins will then be bonded. Probably use brads and glue.

I trenched some grooves in the prototype and had some glass panes made up at Essendon Glass. The glazier didn’t give me grief when I said I was building a TARDIS so kudos to him!  Richard & Leon (TAFE teachers) pointed out with that design the glass may break whist final clamping, so in the new design I’ll rebate in some grooves that the panes can be fitted after the frames are complete.

So, it’s taken 2 weeks of jig making & calculations on the panel saw so that I can exactly and precisely reproduce 56 sticks of timber with precise grooves for fitting. As they say, it’s all in the preparation. I spent the last hour after arvo smoko to complete the corner joins on the 24 horizontal bars. Also made some spares just in case…