The
window holes were cut with a jigsaw (before the MDF decorations were
applied), and were cut ½” larger than indicated to allow for window
mounting. The backs of the windows were not beveled as much as the
fronts, to allow me to slip the glass in from behind.
The
glass was made from fluorescent lighting diffusers of the type seen in
office ceilings. These come in 2’ x 4’ sheets and I cut them to size
with the table saw.
The
cross pieces were made with beading with a ½” x 3/16” cross section.
I
cut the beading to the indicated lengths and then used the table saw set
to 3/32nd”
height to cut notches at each cross point on the beading in a lattice
pattern. At 3/32nd height, you can move the beading sideways
across the blade to make a ½” wide notch. If it were much deeper I would
have needed a router or dado blade. This way the beading lies flat in
front of the glass. The beading was glued into the window frames and held
steady with clamps. I would assume that the original police boxes used a
thick iron frame for strength, as they had to restrain an apprehended
criminal at times.
