Can you spot the mistake?
I hadn't cut the weight pocket out... doh!
The pockets need an arrow shape at the top and and a stepped cut at the bottom. Not easy if I hadn't glued up the frame, but I should have been able to do it with a tenon saw and the long cut down the parting bead rebate with a jigsaw.
The first one I tried with a dremel, hence the burning. The second I used the dremel to cut a Stanley knife blade in to a makeshift saw blade which was a little easier. After the cuts are made a tap with the mallet splits the between the stepped cuts. Giving a pocket cover that only needs one screw to hold it in place.
Update on cutting pockets here Sash Weight pocket cutting
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