Introduction: How to Make a Round Window Frame
There are many ways to make round window frames this is how i made them.
- Boards with desired thickness for the main body.
- Boards with desired thickness for the body with glass stop.
- Boards with desired thickness for the outside casing/flange.
- Boards with desired thickness for the outside and inside trim.
- Exterior grade wood screws
- Glue. (Gap filling, Water resistant, Slow setting) trust me there will be gaps and the glue-up takes time.
- Glue spreader & brush or stick.
- Ratchet straps. (to hold frame in place while glue is setting)
- Glue Claps.
- Tape measure
- Router with flush-trim and round-over bit
- Drum sander ore: https://www.instructables.com/Drill-Press-Drum-San...
- Orbital sander
- Band sander (luxury)
- Hand plane
- Surform plane
- Hand drill
- Drill bits for dowels
- Drill guide for dowels.
Step 1: Making the Templates
Make your templates by drawing the desired diameter circle on a peace of cardboard ore door-skin and divide them until they fit your lumber. I made 6 different templates for:
- Outside flange
- Casing with glass stop
- Main Casing
- Outside trim
- Inside trim
its best to scroll trough the images so you have a idea about the different templates/parts
Step 2: Drill Dowel Holes
Make sure your dowel holes are on the exact same angle & position on each frame piece.
i made a jig for this from some of the offcuts.
Step 3: Glue-up
This will be a race against time and that's why you want to have a slow setting glue. I first did a dry fit to practice before the real glue-up.
glue-up in these steps:
- Glue-up the Main casing ring. (see first picture)
- Cleanup the top of the Main casing for the next glue-up
- Glue-up the Casing with glass stop on top of the Main casing. (forgot to take a picture, see second picture so you have an idea)
- Cleanup the outside of the glued-up window frame since its easier whilst the outside flange is not on yet. (see second and third picture)
- Glue-up the Outside flange on top of the Casing with glass stop. (see forth picture)
Step 4: Clean-up, Shaping, Sanding and Paint
Use the Router, Hand plane, Surform plane, and the sanders to clean up the frame for paint
Do not forget to add a drainage channel shown in the third picture (this will be the bottom of your window).
Now its time for either varnish, stain, ore paint.
Step 5: Mounting the Glass
Now its time to place the glass.
- Stick the glass foam tape on the Casing with glass stop.
- Carefully place the glass op top of the foamtape.
- Stick the glass foam tape to the glass.
- Ad shims to keep the glas in place if necessary.
- Place the glass stops (see pictures)
- Caulk the window in place and let it all dry.
Step 6: Mounting and Water Proofing
Its time to mount the window in the house.
- Cut the house wrap
- Apply waterproofing tape from the bottom to a a little over half way make sure it all overlaps (i forgot to take a picture before i put the window in see first picture to get an idea).
- Put some caulking behind the outside flange.
- Slide the window in its final position (make sure the drainage channel is at the bottom (see 6th picture).
- Secure the window by screwing trough the main frame to the framing studs. be careful not to put tension on the frame.
- Apply the water proofing tape around the top of the window make sure the top side overlaps the bottom (see second and third picture)
- Place the out side trim and add some caulking behind the trim (see fourth and fifth picture)
- Place the outside cladding against the outside trim (see fifth picture)
- Caulk the outside trim to the window and the outside cladding (see sixth picture)