Description: Installing a Lexan Window (trust me, you'll want one!)
Note: Trace window onto
wall panel with pencil. Using a straight edge, measure in Ĺ"
all around so you have a second square just slightly smaller than
the window your installing. Use jigsaw and circular saw with a formica
blade to remove wood from inner cut. The fine blade will prevent chipping
the melamine coating. Also, if you don't have a soft foot for your
tools, you may wish to mask off the wood surface with tape before
cutting to keep from marring the surface. Using Router, route a groove
around the entire edge the depth of the window so as to create a bed
for the lexan panel to lay in. (See the photo above) While itís available,
iron on melamine edging over the inside edge to seal it. That inside
edge will be visible once the windows installed so take your time
here. Trim the edging with a utility knife for a finished look. Lay
the lexan panel into the routed hole and trim with oak using a mitre
box to cut the oak properly. Secure the window in place with the trim,
some caulking, and some #8 screws. Do not screw through the window,
the trim will hold it securely in the routed groove. For a totally
finished look, I trimmed the inside of the window frame with 1/2"
aluminum channel which I cut and angled with my mitre box.
Construction Time : About 1.0 hour