I'm not at my house, so I cannot take any additional photos, but I may be able to assist.
I apologize for revisiting my past Chevron work, but getting designs into a useable block to cut the window insert is very workable.
1. We know the basics of the window, several methods, pick what works for you.
2. Alan's pattern concepts are excellent. Try the method I used for my Chevron finials. i.e., sanding the Chevron pieces down to the angle you want for the sides you want. (brush up on your geometry, google is your friend).
3. You will just need to get the assembled 'block' big enough to the cut the window insert (maybe 1.5" long by 1" wide by 1/2" thick). This will need to be tweaked for whatever you are doing.
Basically, instead of making the segmenting a 'finial' size (.5" OD and .5" long. Make it large enough for a 'window insert" - before cutting the oval.
I sand fairly large sections on my disc sander with whatever angles I need for 3, 4, 5, 6+ sides. As John says, double sided tape is your friend. NOTE: Please be safe, I do not recommend this for those not willing for some excitement! When I sand segmented pieces this way, I never stand in front of the sander, and I always expect for some UFO's - about 10% of the time I am correct!
I hope this isn't too rambling, and I also wish I was in my shop.
Oh, making a cool design the proper size for the window pane will not be the greatest challenge! Its getting it centered so that when turned down to final pen OD size it is where you want it to be. (Hank had an excellent phrase for this in another recent thread, a quote from Wayne Gretzky: Basically... It's not being where the puck is at, it's being where the puck will be. For us, it's not centering the pattern on the outside, its getting a techniques for centering the pattern on the inside, which we can't see until it's turned down). The final photos show one where it was not centered properly.
Have fun guys!
Seems these days my list keeps growing with all these new ideas coming to light and I want to play too.
