I had a general idea of the size and number of windows I wanted, because I had drawn them out on the piece before I took the scroll saw to it. I based them on the window cut outs in the kit.
I set off the smoke detectors taking measurements. Add a 3/4" x 6-1/2" piece next to the door frame, measure the hole height and length, add the 1/4" thickness of the trim wood, subtract the 1/8" mullions x 3... There is still soot coming out of my ears when I sneeze or cough!
Once I was fairly confident in my measurements, I decided to draw everything out in Publisher. This way, I could print it and hold the mock up to the window opening to see if I had measured correctly. Plus, I could then use the pattern to square my frame up. My gluing jig is not wide enough!
I had to cut everything for two frames, one for the outside and one for the inside. I made the cut list, and and just cut the pieces one at a time with my Easy Cutter. I ended up needing 32 1/8" x 1/8" mullions. For those, I broke out the rip saw and taped 6 pieces together so I could cut six pieces at a time.
Once I began gluing the pieces in place, I started to realize that with all of those mullions, the frame was kind of taking on a Mid-Century feel. Whoa! I had to stop and reevaluate my whole plan here! Was Mid-Century really what I was going for? No! No, no, no, no!
Too bad I didn't figure all of this out before I hacked 6 pieces of 1/8" x 1/8" x 24" into 42 1-1/5" pieces.
Phew! Not that I am against Mid-Century in any way. I made a fantastic Mid-Century home in Sims 3 that at last count had about 300 downloads, but that was not my vision for this build!
Where I am trying to go with this build is Modern-Modern. In other words, the Contemporary, current version of Modern. Not the modern that was modern in the Mid 20th century. Make sense?
Oh, well. Whatever. I am not a purist in any sense of the word. I just want what I want and it is not vertical mullions... We'll see what I actually end up with... :0)