I made eight windows for the horseshoe-shaped pilothouse of the 24’ Troller at the NWSWB. Each window was a slightly different quadrilateral shape, most having four different interior angles as well as compound exterior angles. I began by making eight patterns out of door skin and milling the sapele stock to the correct dimensions for the rails and stiles of the window frames. Using my patterns, I cut the stock to length and laid out each of the angled bridle joints. I cut all the joints using a jig on the table saw. After fitting and gluing all of the frames, I routed in the rabbet for the glass and then patterned for each pane. I made eight pieces of compound mitered trim for each window; four to hold the glass in and four to hold the window into the opening on the boat. I installed the glass and inner trim with a flexible adhesive and pin nails. After doing a final fit of each window, I varnished the windows and the exterior trim and installed them.
Pearl Farley 