I wrote this up and put it on another forum. Not sure if I can post link here yet...
So, I cannot take credit for this. I saw something very similar on one of "outofthebluesky"'s videos.
Essentially I wanted some easy to make and robust "frames" for a cutout. These took me about an hour to make. The time is in the drilling/cutting and setup. Once you get to putting them together it goes very quickly.
Here is the finished product:
I used finished topbars. However it would be much better to use an unfinished bar with no kerf or guides I think. The sides are 1/2" dowels cut to 12" in length. The bottom is 7" and is simply a 2x4 ripped down to 1/2" thick (many pieces). The rubber bands I got at staples (Stationary supply store). I've been debating on actually stapling the rubber bands into place so they cannot move but I am hoping I dont have to do that.
Required tools:Saw, Drill & 1/2" Drill bit.
Suggested tools: Table Saw, Vise and Drill with 1/2" drill bit.
Step 1. Make sure you have an empty TBH available for use as a "jig".
Step 2. Gather required items. Topbars, Dowels, Bottom bar wood, Wood Glue & Rubber Bands.
Step 3. Prepare bottom bars by measuring the distance across the bottom of your TBH. Cut 2x4 to this length. Then Rip to 1/2" pieces.
Step 4. If you are using Phil's plans for the TBH, then the dowels are cut to 12" lengths. If not, put a bottom bar in your hive along with a top bar above it and measure the distance from the bottom to the top. Ct dowels to length.
Step 5. Center your top bars on the hive, then use a pencil to mark the inside edge of the sides on the top bars. See this picture:
Step 6. Put the Top bar in a vise and drill just to the inside of your pencile marks. Once ALL the way through, angle the drill to a few degree's past the angle of your sides. See following picture:
Step 7. Put your bottom bars into a vice and drill through each end approx 3/4" from the side. Then Angle the drill. See following picture:
Step 8. Once you have completed drilling all the top and bottom bars. Begin assembling them in the hive. See following:
Step 9. Once you have everything straight, apply your wood glue to the dowel areas. See Pic:
Step 10. Continue to assemble and keep them straight. See pic:
Give them a day to dry, then add the rubber bands and they are done!
Please let me know if you have any questions.