DIY Window Frame Muntin Bars

Written by jonah morrissey
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A wooden window frame is made up of many parts. The parts that separate and holds the glass are called the muntins. Muntin bars are made using a router and specially designed router bits to create a decorative exterior profile and an interior profile that will hold the glass panes. These bars lock together in the centre to create an interlocking cross to divide the window into quadrants. You can apply the procedure to make a basic 24-by-24-inch muntin bar assembly can be modified to create any configuration.

Skill level:
Moderate

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Things you need

  • Router table
  • Muntin bar router bit set
  • 2 stock bars, 1/2-by-3/4-inch, 24 inches long
  • Sanding pad, fine-grit

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Instructions

  1. 1

    Insert the muntin bar profile cutting bit form the set into the router table and lock it in place. Adjust the height to cut the full profile into the 1/2-inch thickness of the stock bars. Adjust the fence to allow for a 3/4-inch wide stock to freely move through the table.

  2. 2

    Run both 1/2-by-24-inch edges of the two stock bars through the router table. The 3/4-inch side of the stock should be flat against the table. Run one side through and rotate the stock 180 degrees to rout the other edge. The 3/4-by-24-inch side that was facing up while running the stock through the router is the top.

  3. 3

    Measure the centre of the length of both bars with a tape measure. Mark the measurement with a pencil.

  4. 4

    Insert the v-groove bit from the set into the router table and lock it in place. Lay the 1/2-by-24-inch sides of the bars flat against the router table, one at a time and run them through the router to notch a v-groove in the centre of each 1/2-by-24-inch side of both bars.

  5. 5

    Insert a the 1/4-inch straight bit from the set into the router table and lock it in place. Adjust the height so that it makes a 1/4-inch deep cut. Make a 1/4-inch wide by 1/4-inch deep cut in the centre of the length of both bars. Make one cut in the centre of the top 3/4-by-24-inch side of one bar and one cut in the bottom 3/4-by-24-inch side of the other bar.

  6. 6

    Interlock the two notched centres from step 5 to assemble the routed muntin bars. Sand the exposed surfaces of the muntin bar assembly with a fine-grit sanding pad.

Tips and warnings

  • Always use sharp router bits to create a clean edges on your muntin bars.
  • Wear eye protection when operating a router table.

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