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I have a shed with a huge window (5'x6') that needs replacing. But it's just a shed, and I'm just doing plexiglass. I figure four panes, so wood around the outside and a cross in the middle. Just cut dadoes into some 1x1 and slide the acrylic in there. (I'm not sure yet about how I'll join the wood).
My main question is: what dimensions should I choose, for the wood, the dado, and the acrylic thickness?
Here's a sketch to make it more clear. The shed has an interior casing in place already, so that's basically a wooden frame, 4" deep. I'll put what I make right inside that.
What I'm picturing right now is 1x1 wood all around, 3/16" acrylic for the "glass", and then ... half an inch deep dado? Quarter inch?
One problem is that the inner cross of wood (muntins?) needs to accept two panes of plexi, so two half-inch dadoes in one inch of wood just cuts it in half. But it would look dumb for the inner cross to be thicker than the outer frame. So can I get away with quarter inch dadoes? Or should I make the whole wood frame 2x2 or 2x1 instead?
Four panes seems like the right balance of work and money (one five-foot-by-six-foot pane would cost a ton).
This is a back yard shed, so I'd like the window to survive maybe a tennis ball or a frisbee hitting it. Not trying to be bulletproof.
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