Instructions for a Glass & Wood Display Case

Framing

• 1

  Measure your window sash for height and width from outside to outside, using a tape measure. Cut two pieces of 1-by-4 lumber the same length as the long side of the sash frame and two pieces the same length as the short side of the sash frame, using a miter saw.

• 2

  Cut a piece of 1/2 inch thick plywood 1 inch smaller in both directions than your window sash frame. For example, cut a 23-inch square to fit a 24-by-24 inch sash. Use a table saw to make the cuts.

• 3

  Apply glue along the ends of the two short pieces of 1-by-4 lumber. Stand them on edge, parallel to each other and nail the two longer pieces to them, overlapping 3/4 inch on either end. Use a pin nail gun and 1 1/2 inch nails, four nails in each corner, through the long pieces into the ends of the shorter pieces to form a rectangle the same size as your window sash.

Bottom

• 4

  Use two wrenches to open the collet on your router, turning the inside nut clockwise and the outside nut counterclockwise at the same time. Insert the shaft of a 1/4 inch rabbet bit at least 1/2 inch tall into the collet, and turn the nuts back in the opposite directions to tighten.

• 5

  Adjust the depth of the router bit to 1/2 inch. Set the router inside the rectangle frame, with the base on the edge of the 1-by-4s. Start the router and run it around the inside lip to create a 1/4-by-1/2 inch rabbet, or groove, along the inside edge of the frame. Turn the router off, and let the bit stop spinning before setting it aside.

• 6

  Use a hammer and chisel to square the four corners of the routered groove. Drive the chisel down, with the flat of the blade facing the outside of the frame to limit the cut. Remove the cut corner.

• 7

  Insert the plywood panel into the grooved face of the frame and check for fit. Remove the panel. Use the chisel and hammer to make any needed adjustments. Apply glue along the groove and reinsert the panel. Nail it in place with one nail every four inches around its perimeter.

Hinges

• 8

  Turn the box over and set the window sash on top with all four edges flush.

• 9

  Fit two 2-inch utility hinges along one long edge of the sash, two inches in from each corner, aligned with the hinge pin centered on the seam between window sash and the 1-by-4 frame.

• 10

  Attach the hinges with one 1/2-inch wood screw through each hole in each hinge, using a power drill.