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post #1 of 4 (permalink) Old 08-12-2011, 06:44 AM Thread Starter
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Default Mortise and tenons

Hi, I'm a cabinet maker in Cleveland TN. I've been called upon to replace a cathedral window in a church. The wood is about 1 1/4" thick and needs to be routed. How do you rout a rounded surface on the inside of the radius and the outside of the radius?

Secondly, how do join the peak of the cathedral window with a mortise and tenon joint.


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post #2 of 4 (permalink) Old 08-12-2011, 07:50 AM
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post #3 of 4 (permalink) Old 08-12-2011, 08:16 AM
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Welcome, Glen

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post #4 of 4 (permalink) Old 08-12-2011, 04:35 PM
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Hi Glen

Inside and outside routing often require two separate templates (one for each side) made after drawing out the window glazing bars full size. These look a bit like the old fashioned sticking jigs used to plane-up sash sticks by hand (although they are obviously curved). I sometims have a similar problem when making curved counters, reception desks, etc. BTW the class of work you are talking about is often performed on a pin router rather than a portable router.

As to joints may I suggest that you try to study the existing joints if at all possible. There are various techniques for jointing glazing bars ranging from end dowelled joints (the 18th century approach) which requires a purpose-made jig to scribe and a second one to drill the dowels to the modern scribed/glued joint approach as shown here which is sometimes supported by glueing a piece of canvas beneath the glazing bars


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