Well I just made up the parts for 300+ frames. I know the general wisdom is that it is not worth it to make them but it seems to have gone quite well. I made deeps and basically just copied on of the frames that I had previously purchased, The only real difference is that I have a slightly narrower Top Bar in my design. They took a bit longer than i thought but this being my first time I know I could shave some time next time. My biggest complaint is that wood from Home Depot generally is junk so next time i'll make sure to get better stock. That caused more waste and some frustration.
The wood cost me $80 which I turned into approximately 650 ends, 300 top bars, and 550 bottom bars. So at 300 frames that works out to 27 cents each. I spent about 8 hours in my shop making the parts. Since i have the time and a well supplied woodshop I feel that it has been a profitable endeavor.
My question is this. Since my top bars are narrower than standard will this cause me problems that I'm not thinking about. ( the ends are standard 1 3/8 so spacing is the same) It seems that the only real difference would be in uncapping the frame that the knife would cut a bit more wax off the cells by 1/8th. I guess that also the frame could be slightly weaker but i'm not sure that is really an issue.
Here are some pictures. You can see one purchased frame in one pic. and the rest all mine.
Thanks for the input.