How to Make Double Glass Windows

Cut the ends of your boards at a 45-degree angle using your miter saw. The 20-inch length must not be affected, and when they lay flat they should look like a trapezoid. The top of the trapezoid should be 16 inches. These 45-degree cuts will make the corners to your window frame.

Position the table saw blade so it is perpendicular to the table, and raised 1/2-inch above the table. Position the fence so it is 1/4-inch away from and parallel with the blade.

Run each board's 16-inch side over the blade using your fence as a guide. You should have an 1/8-inch-wide, and 1/2-inch-deep groove that spans the length of the board. The groove should be 1/4-inch away from one of the edges. Run each board across the saw again so there is another groove that is parallel with the first, on the same side, and 1/4-inch away from the opposite side. These grooves will hold your glass sheets.

Lay two boards parallel, 16 inches apart, with the grooves facing each other. Position another board perpendicularly to the ends of these boards so their 45-degree cuts are against each other, and so the corners are flush.

Drill a 3/32-inch pilot hole through the third board that was positioned. The hole should be one inch from the end, and one inch from each side. It should enter the board that is perpendicular to it between the grooves. Repeat this process at the other end of the board. Drill a 1/4-inch-deep, 3/8-inch countersink hole into the two holes that were drilled on the third board. This will hide your screw heads.

Place a dab of glue over the 45-degree cuts on the board with the counter-sunk holes. The dab should be the size of a dime. Position the corners back together so they are flush, and screw them together using the pilot holes you drilled in the previous step. Let the glue dry according to instructions.

Slide the two glass sheets into the grooves carefully. Fasten the last board to the open ends of the boards that are securing the glass. Follow the same process you did in the Steps 5 and 6 of this project.