Help with window sash bars (muntins)
I am building a barn door with true divided lights for the top section. This is my first window build and I'm working through it. I bought a router set (yonico I think) that has one bit with a single cutter for the cope. The other bit has a cutter for the rabbet and another cutter for the sticking.
I've figured out how to create the muntin, rail, and stile profiles no problem - lots of YouTube vids and some docs out there. But I'm totally stuck on hoe to cope and mortise where the bars intersect. This is the part where the horizontal and vertical muntins cross.
i know I have to cope th end of the bars like I do the rails. However I need the thin divider on the rabbet side and I have to figure out a tennon on this tight end piece.
I've got 8 intersections so hoping someone has been through this and has a creative way so I'm not spending hours with a chisel and doing this all by hand.