The Building

Making the Windows

There are twenty-four windows in the house, sixteen on the first floor and eight slightly smaller windows on the second floor. Therefor the windows could be mass produced. To this end a set of jigs were constructed for both sizes widows. These consisted of a jig to frame the window casing and outside molding, a jig to frame the upper portion of the window and a third jig to frame the lower section.

The window casing and the windows were constructed as a complete unit including the outside moldings and window sill base that can be inserted from the outside into the window cutout. The window unit was then glued to the shell using household Goop. The inside window sill and the window moldings were then glued to the window casing and the shell.

Several different kinds of wood were used. The window casement was cut from 1/16" beech wood. The outside molding and sill was made from white pine to match the siding and the inside window sill and window molding were made from birds eye maple to match the interior molding. Rather than building each window separately, all the parts were mass produced and then assembled. As an example, once the milling machine was set up for making one kind of molding, it was possible to keep the same settings and mass produce all the molding of that type. Thus all the parts for all the windows were made before the windows were assembled.

Click on photograph to enlarge

The photograph on the right shows a completed window casement including the exterior sill and molding resting in its jig. These parts were glued together using Elmer's Carpenter's Wood Glue.
The next step is to construct the windows themselves. Shown on the accompanying photograph are both sides of the lower window being assembled in its jig. The outside frame for the windows is lapped rather than butted to increase the gluing area. The mullions are notched as well as their position on the frame and are glued into place again using Elmer's Carpenter's Wood Glue. In addition one side is 1/8' thick and the other side only 1/16". A grove is cut in the thicker window to hold the glass in place. Rather than using glass, which can easily crack, the glass was cut from clear CD jewel cases. This plastic can be cut with the Jarmac table saw. However the heat from the saw leaves a very rough and partially melted edge which has to be sanded smooth.
Each half of the window is then sanded to a smooth finish and to make sure the mullions have a flat surface. The plastic serving as the glass window pane is then put in place and the two halves assembled for a position and size check. The photograph on the right shows the upper window in place. In the real house the upper window is sealed in place and only the lower window moves up or down. Thus an extra strip of wood is glued in place to hold the upper window in its proper position. This extra strip also allows the lower window to slide up and down smoothly.
The next photograph shows the lower window in place for a position and size check. This window is carefully sanded so that it slides smoothly up and down. The parts for the complete unit are now ready for painting. The unit is given two primer coats of white outdoor paint and two coats of high gloss finish paint. The mullions are painted prior to the installation of the "window glass". The two halves of the window are then assembled with the plastic window in place and glued with five minute epoxy.
The photograph on the right shows a complete window unit ready for mounting on the shell. The view is of the interior side of the window.
This photograph show the exterior side of the window including the window molding and exterior window sill. The lower window is partially raised.
This photograph shows an exterior view of a living room window glued in place. Behind the window you can see the Indian shutters partially open. You can also see that the house siding is not as yet installed.
The final photograph shows an interior view of window in the guest bedroom. The interior molding and sills are now in place. We are not aware of another dollhouse that has actual window sills on the inside.

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