The task we did next, was to measure every window again, using a framing square and precisely get all the data that describes the state of our framework, with all the wobbles and skews! All this went into a spreadsheet and analysed all the numbers. We have concluded a final set of sizes for all 12 windows as follows ..

A.Great Room 1640mm by 1598mm
A.Kitchen 1640mm by 1598mm
C.Entertainment 1640mm by 1598mm
F.Utility 1030mm by 1598mm
H.Bedroom 3 1640mm by 1598mm
I.Bedroom 3 830mm by 1598mm
K.Bedroom 2 1640mm by 1598mm
M.Bedroom 1 1640mm by 1598mm
N.Great Room 1030mm by 1598mm
O.Great Room 1640mm by 1598mm
P1.Great Room 1640mm by 1598mm
P2.Great Room 1640mm by 1598mm


We managed to arrive at a fairly consistent size, by making adjustments to the clearance gaps between the glass and the framework and having slightly different thickness for the pads that the glass will be sitting on. We are having to make our plastic pads ourselves on our 3D printer because our glazing units are tripled glazed and they are 50mm thick, three 6mm panes and 16mm warm bridge spacers. Even if we could have bought them somewhere, our window sills had the slope starting only 40mm from the back edge, which means the plastic pads needs to get thicker at the front. So we will use our supply of ABS plastic strand (we first doubled checked the structural strength of this type of plastic and discovered that it is way strong enough!), design and print a 55mm wide by 100mm long pads with it getting thicker after 40mm from the back.
And finally, the glass will be stuck firmly on to the aluminium bars using double sided security tape which is 3mm thick by 12mm wide.

We placed the order for the glass today at a cost of about £5000 (To buy 12 oak windows would cost at least £12000).

By Shaun

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