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This project appeared in our September 4, 2010 Newsletter.

We've had funky little house numbers on our house since we moved in three years ago and never really liked them. Recently we added a new porch light and now they really looked bad. I decided to make a nice frame for a new set of numbers. A couple of years ago I made a really nice screen door and decided to make the house number frame match it.

Materials:

  • 3/4" X 2 1/2" X 55" Clear Fir
  • Exterior Glue, Tightbond III
  • 3/16" X 9 3/8" X 15 1/4" Hardboard
  • 4" High House Numbers
  • Minwax Gel Stain, Antique Maple
  • Minwax Helmsman Spar Urethane, Clear Semigloss
Tools: Cut List:
  • (2) 2 1/2" X 15" Fir
  • (2) 2 1/2" X 12" Fir
  • 9 3/8" X 15 1/4" Hardboard

Using the tablesaw cut tenon's as shown above 1/4" deep on the sides and 1/2" deep on the edges.

Cut the cheeks using a tenoning jig.

Drill the mortises centered, 1/2" down from each end with a 1/4" Forsterner bit.

Square them up using chisels.

Glue the pieces together and clamp.

After the glue has dried sand all surfaces.

Route a 3/16" deep dado around the back of the frame using a straight router bit.
Set the fence so the dado is 1 1/8" in from the inside edge.

You'll have to move the fence and route around three times to remove all the wood.

Test fit the hardboard into the frame to make sure it fit.

Make eight 3/8" tapered plugs using a taper plug cutter. Drill into scrap end pieces of fir.

Cut the plugs out of the pieces with a band saw or hand saw.

Using a drill press drill eight holes, two in each corner, 1 3/4" in and one 3/4" down and one 2" down.

Glue and tap in the plugs into the eight holes. I like to align the grain of the plug with the grain of the board.

After the glue dries flush cut the plugs with a flush cut saw.

I stained the frame and painted the hardboard insert. I applied two coats of urethane and glued the insert into the frame.
I routed two hanger slots into the back of the frame using a Hanging Slot Router Bit.

Use masking tape to align the number and keep them straight.

I hung it on the house and it looks so much better then the little funky numbers that were there before.

We hope you liked this project. If you build it and your friends ask where you got such a clever idea, please tell them that you got it at RunnerDuck.com.




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