More progress….
My original plan was to use a chisel to cut the round ends to the rabbet cuts to a square shape that would allow the screen frames to fit into the stiles. However, I changed my mind and decided to sand the screen frame corners round to match the rounded rabbet cut ends.
That’s 150 grit sandpaper. I used a block under the frame to be sanded to raise it off the worktable. I used a few different blocks to vary the height from poiece to piece to adjust where the work piece was on the sandpaper. The scribe lines were made using a scrap of aluminum with a 3/8” hole drilled… same size as the router bit used on the stiles.
In theory each stile and each frame should be pretty much identical in dimensions. However, in practise that does not always follow. So I have assigned a letter or number ID to each piece, made a map and will follow that pattern.
Here’s an idea of what this will look like. It was slightly tricky rubber banding this together with only two hands.
Next, I need a top and bottom. Not sure what they should be named, so I’ll just call them the top and bottom. I don’t want end grain showing so I need to cut strips to cap the end garin. These will be glued to the main piece and I’ll use dowels to make holding them in place easier. No metal fasteners. What I mean will be clearer as work progresses.
I have a jig for aligning the dowel positions and for holding the drill bit perpendicular to the edge of the pine board. It utilizes hardened steel inserts for three sizes of bits; 1/4”, 5/16”or 3/8”. It clamps and self centers.
Once those holes are drilled I used a couple of steel dowel centering pins to transfer the position of the holes to the piece of wood that is to be mated. Here are the pins in place. The smaller piece of wood has already been placed over the pins and tapped to allow the pin points to mark the positions.
I use a couple of clamps, using a light clamping force, to hold the two pieces of wood in alignment, then tap the upper piece to contact the dowel pins. There are other ways to get the alignment, but that is what works for me.
Then I drilled the small block on the drill press.
Last image for now… The small block is glued to the larger piece with assorted clamps to hold alignment. The dowel holes have just enough sloppiness to allow slight misalignment of the two pieces. The sideways clamps help with that. The two larger clamps provide the clamping force to make a good bond between the large and small blocks.