Eye Brow Windows #2: Building The Jig or Form

We measured all the windows and they were pretty uniform. Less than 1” difference here and there. So I took the largest measurements and made all the eye brows the same size. The installers will be responsible for trimming to final size.

Taking that into consideration, I started by getting a 3/4” sheet of plywood and laying it on my workbench. I then took the template I got from the installers and figured out the circumference of my arch over the windows. I also figured out the final width of the windows and made some supports to attach to the plywood. These supports are to hold my side pieces to the exact width of the windows.

I then cut my arch pieces to apply to the form. I made 2 so I could attach one to the plywood and one to place up higher to keep the eyebrow itself perpendicular.

I then cut my side pieces. These sides are 43” high and taper from 1 1/2” at the bottom to 32” at the top. The plywood is 3/8” birch. I then attached them to the form and screwed them to my supports.

Next: attaching the arch piece to the sides.

-- Jerry--A man can never have enough tools or clamps