Replies

1. 
   John_Nolte | Jun 07, 2000 04:29pm | #1

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   William:

   As a general rule, shape edges on big pieces, and then cut them into little pieces. For muntins, the process will depend on the tools you have available. Use the shaper to cut the visible profile of the muntin on the edge of a flat board planed to the muntin width. Cut the rabbet for the glass next with a router (router table)or a dado, grooving both sides of the board. Finally cut off the complete muntin, but let it fall off on the outboard side of a glue joint ripping blade. Do not try to cut it off between the blade and a fence. If you are making lots of pieces, all of them should be the same width to simplify setups. You can work both edges of the wide boards. When they get too narrow, glue them up or use them for something else. This method requires one machine for each cut.

   An alternative method is to cut the rabbets first, forming a tongue. Then cut off each piece. Make a grooved holder 4" wide or wider for the muntin blanks. The tongues should have a snug fit, and there must be a stop at the end of the groove. Use it to push the small pieces past the shaper cutter.

   Be sure that all your setups are completely guarded so that it is not possible to get your fingers near the cutters.

   John