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Step 4Do some cutting with your hacksaw
Measure your windows carefully and then add 6-8 inches so that your rod extends several inches past your trim on both sides of the window. I measured 100.5 inches from trim edge to edge so I added 6 inches and cut at 106.5 inches to give me 3 inches of overhang on each side. Mark and cut your conduit, (it's really pretty easy to cut with a hacksaw,) then sand or grind off the rough edges.
Now try twisting your 5/8 inch dowel rod into the conduit. It will probably be a little tight so you may need to sand it just a little. Don't try to use 1/2 inch dowel or it will be way too loose. Once you have a good fit, clamp it down and saw off two little 1/2 inch stubs. These will be used to attach the finials to the conduit.
Now try twisting your 5/8 inch dowel rod into the conduit. It will probably be a little tight so you may need to sand it just a little. Don't try to use 1/2 inch dowel or it will be way too loose. Once you have a good fit, clamp it down and saw off two little 1/2 inch stubs. These will be used to attach the finials to the conduit.
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I was able to get the EMT cut at Home Depot. I had to wait around for a long time for someone in the plumbing department to show up and use the pipe cutter (and then he said he wasn't supposed to cut EMT) but I was able to get away without having to buy a hacksaw. Note that the pipe cutter narrowed the inner diameter of the cut ends. I had to file down the lip before I could get the dowel in. Luckily I had files at home.
My store didn't have 5/8 in dowels, so I got 1/2 in instead. It fit snugly into the EMT without sanding. I applied a little wood glue to the ends of the pipe to make sure the dowels wouldn't fall out.
I tried drilling holes into the dowels at first but could never seem to get it centered. After 2-3 tries I gave up and decided to glue them on instead. I didn't really stress test them, but they seem to be very securely fastened. It may have helped that I was using wooden cabinet knobs. Metal knobs probably would have required something stronger (e.g., epoxy)
If this curtain rod would be used in a child's room how about attaching a small toy, like a Hot Wheels car, a small doll, wooden alphabet blocks, Scrabble letters, a bunch of pencils, thin markers or crayons shoved in the rod, pieces of a game where some of the pieces are lost so the game is useless? In Dad's Man Cave, if he's a golfer, put a golf ball on the end for a finial. For a hunter, an empty cartridge or a bunch of empty cartridges glued together, a small basketball, football, soccer ball for the team sports player (or observer LOL) would customize the rod.
Orbs or other shapes, depending on the shape of the baloon) can be made from starched string or yarn wound around a balloon inflated to the size you want the finial to be. Let it dry, pop the balloon, and glue the orb to the end of the pipe.
Styrofoam balls could be painted (special paint needed) or decorated in a variety of ways and attached.
These are just a few ideas off the top of my head. I'm sure you and anyone who reads this will be able to come up with many of your own.
Thanks VERY much for posting this. I just knew there had to be an inexpensive and simple way to make my own curtain rods but not having building construction experience, I was unaware of the products you used. I'm sure there are many a homeowner for whom you saved many dollars on new curtain rods. We should all get together and buy you a lobster dinner. LOL Seriously, thanks for posting such a great idea that was well done in the sharing here.