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  1. #1
    Join Date
    Jun 2011
    Location
    Horsley NSW
    Posts
    10

    Default Fly Screen frame with Merbau rounded edges

    I have some 42/19 Merbau timber left over from a screen i built, and i want to use it to make a couple of simple rectangular frames(possible cross brace) to stiffen.

    I have 2 french timber doors opening outward to a deck, and want a thin framed screen inside them to stop the bugs, but not detract from the view from inside.

    I want to join the lengths with the longer lengths met at the top and bottom by the cross members.
    Or should i run the top and bottom lengths the full width and make the longer side lengths butt between the top and bottom?
    I am intending to use 2 x dowel inserts for each butt joint, but in assessing the timber, i have noticed the timber is milled to light round corners.

    Should i remove the round edges at the locations of the butt joins to ensure a clean join, or not worry about a slight gap between the joins?

    If i need to remove the round edges, what is the best way to do this?

    I do not have a bench saw, but only a circular saw and a router or hand saw to do this.

    I tried to router 42mm of the ends of a test piece of Merbau, but could not get a smooth consistent finish as it was at the end of the length.

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  3. #2
    Join Date
    Jul 2005
    Location
    Oberon, NSW
    Age
    63
    Posts
    13,354

    Default

    I'd remove the round-over at the joint, even if only because it would look so much more professional!

    If I understand what you want to do correctly, it doesn't really matter whether it's the rails or stiles that run full length.

    To my mind, given your tool list, the easiest way to remove the rounded edges for the joint would be to cut your two "full length" pieces longer than you want, by maybe 6"-12" and clamp them face to face.

    The idea being that this'll give you a couple of inches of waste material at each end, so you can mark out where your joints will be, use the router to remove the material (the waste piece & the material being clamped together to double thickness will help keep the router sitting "flat & square" during the cut) and after you've routed both sections, dock 'em to the desired length.

    Easier done than said!
    I may be weird, but I'm saving up to become eccentric.

    - Andy Mc

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