French Windows for Peter Pan

I am building an 8' x 12' french window with an arched top for a production of Peter Pan. I am an intermediate carpenter at best, any suggestions on the best way to build something strong but good looking from both sides when it opens? I was going to cut the top arch out of 3/4 plywood and then attach it to a frame made from 1x3, but how can I easily join the wood, while creating a strong frame that is beautiful to the eye from both sides. Also, any tips on how to create muntins and mullions easily. I need simple, strong, and good looking, oh and cheap would be nice.

when I help biuld the window and window box this what we did, the box was 3 feet deep and 2 feet hieght and was as wide as the window and we used aluminium right angle (4") to attach the window to the window box also the top arch has to be open so you can get the cable through to fly Peter

My suggestion would be to make the window out of 3/4 and 1x as you are thinking, and then to face both sides in 1/4 ply - glued, stapled, and then routed to fit. For muntins/mullions, I have had good luck using 2x stock ripped down to ~3/8" x 1.5", cutting for a tight fit, and then simply bridging the gaps with a T40-size staple on each side.

I'd say it's time to comfortable with the half-lap joint. You'll want a dado blade on a radial arm saw (first choice) or table saw. That way you can assemble your outer frame, keeping at 3/4" thick. 8x12 is pretty big - you'll need really nice, straight lumber. I'm thinking you may want to skin both sides with lauan to create a sort of stress-skinned unit to keep itself rigid, at 1.25" thick.

For the mullions, a common way is to rip 1x into 3/4" strips (so you have 3/4" x 3/4"). Lots of half-lapping to make them into a grid. Each piece runs full-length and is half-lapped across every other one. Then run a small cove route inside each square to give it fanci-ness.

We just completed that show. Ours was 6' x 11'. Basically we half lapped 1 1/2" x 1 1/2" stock and made the arch out of layered 3/4" ply. You can see the windows behind out captain hooks rowboat in the photo.

We just happened to be build one as I described yesterday. Here's a close up. May or may not be appropriate for the large size of yours.

If you were putting plexiglass in the window, and seeing the thickness of the muntions/mullions wasn't a priority, simply doing them with tape or paint lines on the plexi would be an option.

However, 4' wide x 12' tall window halves would be rather flimsy if all they had for framing was the outside perimeter. I'd go with nice, tight half-laps so that the muntions/mullions can add a bit of stability to the piece.

Ok I like the half-lap idea, and and the stress skin for the frame. What is the best way to actually attach the muntions/mullions to the frame?

Half lap the edges on them as well so they overlap on the frame. When I did this it was exactly like everyone else has done, then glued and stapled at the edge.


Via tapatalk

A few related things: panes are not required for the windows and will give your flying director options for where to hide fly wires for hookups in the nursery.

Don't forget that for Pan's first entrance, the flight happens from US of the window to DS. tHe fly wire will need an unobstructed path to pass through so the arch of the unit must be "topless". The windows should also be hinged to swing DS to avoid snagging the fly wire for the first entrance as well.

Sorry if I went all off-topic, but I always hate taking a Sawzall to otherwise lovely sets for these reasons.