Eye Brow Windows #3: Building the Windows

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Blog entry by cabinetmaster posted 06-21-2009 05:27 AM 11206 reads 0 times favorited 5 comments Add to Favorites Watch
« Part 2: Building The Jig or Form Part 3 of Eye Brow Windows series no next part

Ok, now for the actual building of the eyebrow windows. This is where we left off. Remember that the side pieces are 3/8” plywood 43” tall, 1 1/2” at the bottom tapered to 33” at the top.


After attaching the side pieces, I was able to measure around the circumference of the arch and determine the length of the top pieces. I used 3/8” bendy board (flex-core) and cut a slight angle on each end where it attaches to the plywood on the sides. The bendy board goes from 33” on each end to 43” out in the very center. I again radiused this off the template furnished by our installers. I then glued the bendy board to the plywood with titebond III glue and attached a cargo strap to pull it tight to the plywood and also to keep it tight to the form itself. (If you look closely in the center of the side pieces you can see the hole in the support where I placed the hooks). When the glue was dry, I took off the strap and attached a 5” piece of 3/8” plywood over the joint. I used laminate glue to attach this piece and used some 5/8” staples at an angle to hold the bendy board and plywood together for support.


I then re-attached the cargo strap and and used some Bondo to strengthen the bendy board. After the first one was done, we sent it out to the jobsite to check the fit before making the others.

After the first one was test fitted on site, I made a slight change to the others. I decided not to use bondo since it took so much and was very time consuming. I cut 5” wide strips of 1/8” masonite and used contact cement to glue them on the bendy board. I put a total of 3 around each arch and this was very sturdy and kept the arch solid. You can see in the following picture the piece that I added to the top of our first window. I attached the others where I had used the Bondo on the original.


And here is the completed window ready for the veneer.



Next: applying the veneer.

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

5 comments so far

View Karson's profile


35125 posts in 4428 days

#1 posted 06-21-2009 05:37 AM

Nice tutorial. I probably will never make one. But I’m enjoying your trip.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware soon moving to Virginia †

View a1Jim's profile


117126 posts in 3605 days

#2 posted 06-21-2009 06:00 AM

Hey Jerry
It’s a joy to see a master at work. great info, well done

-- wood crafting & woodworking classes

View cabinetmaster's profile


10874 posts in 3586 days

#3 posted 06-21-2009 06:04 AM

Thanks Karson and Jim. Glad you are enjoying the trip…....................LOL

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

View Elaine's profile


113 posts in 3651 days

#4 posted 06-21-2009 12:31 PM

Okay Jerry, I’m learning….I’m also trying to figure out how many tools I can’t buy if I don’t learn enough and hire you to redo the kitchen? :)

View RBWoodworker's profile


441 posts in 3379 days

#5 posted 06-21-2009 06:56 PM

Hi Jerry!!
Looking great!! I’m watching this closely, since I an doing radiuses now..everything I can learn by watching others is more knowledger for me to use for my own projects..thanks for sharing..looking forward to the next series

-- Randall Child

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