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I'm currently working on a window that is 2 feet x 4 feet. At what point do I begin to install the steel reinforcement?
When a panel is larger than 2 feet, reinforcing should be added horizontally approximately every 12 to 18 inches to keep the window from sagging or buckling from the pull of gravity. After regular soldering is completed, you can begin to mount the reinforcing bar, which should be one continuous pieces from the left side to the right. The bar is soldered directly to the back of the window to all of the seams or joints that it passes over. Preheat the bar at the point where it will be soldered to the seam to help the solder form a good bond with the bar; then solder directly to the seam on your panel. Also make sure to solder it to the edging around your window. If the window will be inserted into a wooden frame, also notch the back of the frame so that the reinforcing bar will fit into it. This will also add extra support to the window.
Two things: First, the question did not specify which of the dimensions was horizontal or vertical. Is supporting rebar always "horizontal" or should it span the short dimension of the window? Second, I think the option of Re-strip needs to be addressed here, since many designs do not lend themselves to big straight lines of re-bar.