This was an unusual one-of-a-kind job. It seems that when the house framing was modified for the oval window install, the interior wall was bowed in. So the distance from the window frame to the interior casing changed dramatically as one moved around the oval casing. The casing had been fabricated from two custom made flexible moldings, with a rather sloppy joint. We used an oval router jig, three different router bits, and a sheet of baltic birch plywood, to copy the existing moldings. The last step you see is sizing a flexible molding to tie the window to the new casing.

Newton, MA

Click on the first image for detailed explanation of the process.

  • Here is the window as we found it. There was no trim to connect the window to the casing.
  • The casing had been fabricated from two halves of flexible molding, with a rather ugly joint.
  • On the left side of the casing, the window was 2-1/8” away.
  • On the right side, it was 2-5/8” away. (Reading the tape upside down.) The wall was bowed!
  • Using a router with an ellipse cutting jig to fabricate a rigid casing from baltic birch plywood.
  • A close up view of the new casing.
  • The new casing, ready to install.
  • We turned the casing upside down, and fitted a piece of flexible molding to tie the casing and window together.
  • Installed, and ready for paint.