I could use some master advice. I have built and glued wood framing members for a bunch of spanish cedar storm windows. The four corners are connected by bridle joints. Photos attached. There is a rabbet on the inside edge of both stiles for the track to seat. There are vinyl tracks that sit on the inside edge of the 2 stiles. The single glass window panes are housed in an aluminum frame with plastic guide plugs that are in the upper corners of the panes, and ride/guide in the track on the stiles. Fairly typical set-up. Unfortunately I managed to narrow the full width of the completed window(s) by 2/16". That translates into the length from the inside edges of the stiles to be 2/16" less. That is causing the window pane to bind in the vinyl dust seal of the track as you try to move the pane up the channel track. There is too much forcing pressure for me to let it stand like this. I have already seen the corner plugs binding and snapping the corner plug piece. Disassembling the storm frame is not an option. Recognize that if I take 2/16 off the left inside stile, I also need to do the same to the rabbet. Otherwise the track will sit proud of the rabbet edge. I do not have to cut both stiles. I can choose one stile and do a 2/16" cut reduction. The inside edge (edge #1) is visible to the exterior so it needs to be clean cut. The rabbet (edge #2) is only visible to the interior of the window.
Options??: I could possibly attach a long guide fence and a router bit with bushing for edge #1 and then repeat at shallower depth for edge #2. Then use chisel to clean up last 1" at top and bottom of a stile. Hoping someone has advice for this or other options. Any "be careful" comments are appreciated.
- Rabbet stile at bottom corner -1.jpg (478.29 KiB) Viewed 597 times
- Rabbet stile at top corner.jpg (675.66 KiB) Viewed 597 times
Last edited by TFF on Mon Feb 11, 2019 10:21 am, edited 1 time in total.