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Making your own window grills

djj | Posted in Construction Techniques on November 4, 2004 09:20am

Got a revised bid today for Marvin Integrity window package. Marvin doesn’t make a round top window sunburst grill pattern that has multiple arcs in it in the integrity line. The lite pattern is the spokes with one arc in the center regardless of the size of the roundtop or the lite pattern of the window you are mulling it to. Marvin will do a custom grill in the pattern I want, which is actually a stock pattern from the Marvin line, but they want a $350 upcharge per grill. Mind you this is just a snap in grill made out of half-inch pine, and the $350 is about what it would cost to upgrade the whole window to the regular Marvin line, but it wouldn’t match the rest of the windows. This will add $700 to a $13k package.

So how tough do you think it would be to route an extra arc and glue the segments in. The profile is a trapezoid 7/8″ wide x .5″ tall. See the attached image where I would be adding the blue line.Thanks!

Dennis

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  1. User avater
    jagwah | Nov 04, 2004 09:35pm | #1

    Where are you at? How many windows?

    Honestly for $350. I know you can do this cheaper. Take the time to create a jig for any routing and heck the savings from 3 would by you a Delta 14" bandsaw.

    You could bandsaw the arc, lay it in your jig, route to perfection and hand cut any dadoes for a fit.

     

    1. djj | Nov 04, 2004 10:40pm | #2

      Jagwah,

      I'm in Iowa. I will need to modify the grills for two windows, so if I buy them it will add $700. I figured for that kind of dough, I could spend some time making them and still be ahead. I have a circle jig for my router but I don't think it will go big enough. Making a jig to cut the arcs wouldn't be too tough. Even if I don't get the profile perfect, they will be 7' off the floor so an NBA player would probably be the only one who would notice. 

      Regards,

      Dennis

      1. User avater
        jagwah | Nov 04, 2004 11:25pm | #3

        At that height all that you need worry about is the appearance of balance and proportion.

        I had a client last year that wanted her big front windows to look like a Currier and Ive windows with the multipanes. I milled strips and glued them in between the horiz. mulls making eack 3'0" x 5'4' 2 over 2 double hungs look like 6 over 6 from the street. With the curtains drawn to hide them on the inside the outside looked fine. An illusion but the same look as if they were really multi paned units. 

        1. marv | Nov 04, 2004 11:52pm | #4

          If this is a hijack please let me know and I will delete.

          I have Caradco windows in my house and the windows have inside grills.  They have cheap push pins to hold them in place.  They are forever falling out and getting broken. 

          If I make some replacements out of oak (not the original pine), can I glue them to the windows to keep them from falling out?  Does anyone have any suggestions for keeping them removable and holding them in place better?You get out of life what you put into it......minus taxes.

          Marv

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