We employed the use of a trammel arm and templates to match the curves and make the replacement section of sill from Accoya.

Once again, we were grateful to the folks at Mafell for offering a solution before we realised we even had a problem. We made use of their auxiliary fence for the LO65 router to give us the micro adjustment and offsets we needed to make everything accurately and repeatably.

There were of course still plenty of areas in which a good-old-fashioned razor sharp chisel and a practiced hand were the only way round the problem.

There were other times when offcuts of ply were the answer!