A Tricky Hinge Saga...

 

 Fixing A Mistake...

I Left You a couple of weeks ago, Dear Readers, with the comment that "All" I had to do was repeat the just described window process for the final large window with the opening lower panes. I had it all figured out! I charged ahead with confidence of easy success. The frames were already cut and just needed the glass panes prepared.

The glass panes were quickly cut and the leading added.

The window opening was cut to receive the hinges and holes drilled.

The hinges went on with no trouble at all!

 

 

I had decided to begin with the left hand window pane

 as it would be more challenging to hold it in place

 while screwing the hinges into it...

 with nothing behind it to push against... 

and my hand awkwardly in the way...

 

The frame was prepared for the glass...

The holes were drilled...

But when I tried to screw it into place, 

I could not get the screws to grip the wood well enough 

to tighten down on the hinges!

 

I realized I must have used the wrong drill bit

 and the holes would need to be filled and re-drilled!

I tried using "wood putty" hole filler...

(see the frame on the left above)

But it was not strong enough for the screws to grab it either.

 

Here you can see the puttied holes re-drilled....

Alas, they were still too loose.

 

 

So then I tried filling the holes with toothpicks....

 But they were still not "tough enough" to grab the screws.

 

 I needed small dowels.... 

and discovered that the tip ends of spindles 

were the right size if I whittled them a little bit!

This all took days and days... 

waiting for the glue to dry before re-drilling....

And I discovered that the screws in the

 newer packages of hinges were a tiny bit

 smaller in width than the older kind.....???!!!

No wonder it was too loose with the drill bit I used!

With the smaller bit it needed a lot of "torque" 

to get it all the way screwed in.

The only way to get enough pressure applied 

was to remove the Great Hall Door panel...

Lay it flat on the work table with support for the window pane....

And put my weight into the screws!

One by one I got them tightened all the way !

The hinges no longer wiggle on the screws!

I reattached the Great Hall Door panel....

And proceeded to complete the rest of the window...

 

First attaching the interior frame in the wall opening...

 

Then gluing the outer frame with the upper glass panel in place.

 

And "All" this took, Dear Readers, 

was about ten days of trying and trying again...!

But I got it done!

And it wasn't the hinges fault....

The tricky part was in the screws!