Build Window Transom

Tools:

ladder
folding rule
level
bar clamps
portable workbench
5-in-1 painter’s tool
awl
hammer
adjustable wrench
pull saw
pencil
engineer’s square
large drill bit
spring clamps
caulking gun
table router
miter saw
orbital sander
drill
glazier’s points
towel
safety glasses
dust mask
salvaged pine
dowels
glass
hardware/latch
glue
glazing

1. Using a ladder and folding rule, climb up and measure all of the dimensions of the transom; length, width, height and position of the pinion holes for the hinge pins (figure A).

2. Trim any damage from the recycled lumber with a miter saw. Be sure to wear a dust mask and safety glasses when using power tools.

3. Cut lumber to match the transom dimensions. Cut the lumber in half down the center to make the stiles and rails.

5. Change the router head to make the mirror image of the profile. Use a scrap piece of lumber as a test piece first to see if you have the settings right (figure B).

6. Mill the counter-profile into the ends of the vertical pieces to create a cope joint. Apply wood glue to the joints, then assemble the transom on a flat work surface and clamp together with bar clamps until dry (figure C).

7. Drill holes into the ends of the transom and insert glued dowels to secure the joints (figure D). Trim off the dowels with a pull saw to fit flush with the frame.

8. For added strength, drill holes through the sides of the frame bisecting the first dowels and insert smaller dowels to act a pins (figure E).

9. Sand down the pins and joints with an orbital sander.

10. Drill holes for the spring pins in the sides of the frame and insert the spring pins (figure F).

11. Fit the glass into position and use glazier's points to secure it (figure G). Use several points along each side, then press them into the frame using a painter's tool.

12. Apply glazing to the glass where it meets the wood.

13. Fit the completed transom in the frame and test rotation (figure H). Stain or paint to match doorway if desired.