How to make a round window?
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have it made cheaper then you can make it
Hoo boy and whew!... I'll answer your question just in case you're really, really wanting to do this.
The tools alone will cost you an easy $5000.an open arm moulder, a steam cabinet, convex and concave planes, cabinet makers saws, bending templates ...and... a damn good book on the subject like, George Collings "Circular work in carpentry and joinery" to get you started.
Please go for it! Our country desperately needs people with this kind of skill to save our rarest buildings.
1. If you are to make it, and are not experienced in doing this, it will cost you more for a less quality product.
2. If you purchase a custom designed window it will cost more but you will have a high quality window.
3. If you go with standard shapes and sizes it will cost less and you will have a high quality window.
personally, if you can't find the "Circle" you want then maybe look into some Stock hexagon shapes, as well. They are still pretty popular and most suppliers provide a lot of stock sizes. I would always look to stock before moving upward.
If you just want a tiny one-I saw a photo once where they used heavy glass pie plates-it was kind of cool, but you can't really see out or anything. They were sealed in a round hole with clear adheasive (like locktite)and edged in wood.
The simplest way to do this would be to build an octagon or decahedron using wood the thickness of the window. The wood needs to be wide enough to accommodate the circle you are going to cut. Join the ends with a tongue and groove joint. Attach the frame to a piece of 3/4" MDF or plywood using double-sided tape or screws in the waste areas. Use a plunge router and a circle cutting attachment to cut the inside rebate for the glass. Reset the radius and cut the outside.
If you can make one of these without me providing the minute details, then go for it. If this makes no sense at all, then get a pro to make one or buy a ready made to the closest dimensions.
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