In case you've been losing sleep over how those GeoStudios windows were made, here's the story. First, I could have went with triangular windows in the GeoStudios (much easier), but the idea of a round window had greater appeal to me from day one. While the challenges to building a round window frame are unique, I feel the reward is worth it.
First you need your medium. I chose 1x8 by 8’ long regular lumber. Then cut it into three equal lengths and made it into a triangle. The triangle is not only glued together, it also has metal reinforcements in back to hold it all together. (A couple of lost frames showed that glue alone is not enough.)
Then I routered a circle into it. (Being sure not to router over the metal!)
My circle jig (not the square dance) is just a short piece of plywood with the outline of my router cut into it. And it reaches to the centre so I just spin around that point. The hardest part is finding the centre. That's basic math. Once you got that figured out you’re off to the races.
The finished frame, sanded and ready for priming and finished with elastomeric paint. This triangle is from my previous red & white dome many of you have seen. It will be re-purposed as a window triangle for the campsite dome.
Gilles Leclair is the founder of GeoStudios. Somewhat eccentric, fairly environmentalist, politically aware, he believes the world should have more off-grid communities... many more.