dd how it makes so much sense. Probably why I couldn't think of it. Thanks for that.

Andy

TO MJfurniture
 now that all the kidding is over, lets explore making the jigs.

Years ago, I had to replace some old muntins and mullions in a sash above my son's barn/carriage house (100+ yrs old)

After checking about ten local lumber yards in vain,I resorted to making my own. I ripped several lengths of sugar pine to approximately 1-1/2" square . Then I crosscut about 12 'billets' each a few inches longer than finish length.

The 'jig was a long flat board with a recess routed (or dadoed) along it's center about 1/4" deep' and just wide and long enough to accept the billets. Add two nails at the 'waste' ends to steady the stock in place

Using an ogee router bit, I created each side of the muntin's shaped edges.

Next, do all the rest of the lengths needed (And a few extra)in the same manner.

The next operation consists of ripping the left and right rabbets in each muntin.for the glass mold on the tablesaw.(USE PUSH STICKS)

The trick to keeping this operation working without the work piece rocking in place after the first rabbet is removed and before cutting the second rabbet, is to make a 'filler'piece to
fit under and in the first rabbet's cut, while rabbeting the muntin's second side.

The glass mold can be made similarly, but don't cut any rabbets.
( OR. buy the molding in Home depot.) Steinmetz