IÃ¢â‚¬â„¢ve been offered a job building 11 removable storm windows for a high-end remodeled old farm house. The homeowner wants to use 5/4 x 2 and 1/4 poplar (just like the screens he has in now) for the frames and horizontal center mullion, with custom made double pane glass. These are 62″ x 32″ windows, and my gut tells me that the frame needs a good mortise and tenon joint on the outside corners.
IÃ¢â‚¬â„¢m a trim guy and I was ready to buy a tenoning jig for my table saw and jump all over it until I talked to a friend who used to build furniture. He told me that even the best tenoning jigs are a pain to calibrate so it might not pay to use one for 11 units… not to mention the vibration.
These are going to be some heavy windows, going in every fall and then back out in the spring. I can see biscuits for the center mullion, but not the corners. ThereÃ¢â‚¬â„¢s a good chance I could get access to a nice shop with a couple of unisaws with beisemeyer fences, tenoning jigs, jointer and etc.. But now I wonder if even that would cut it.