Re: side bar design
If you transported a box with frame with only 1 inch wood at the top the bottom of the frames would slap together and crush bees. You would need a projection of some sort about 3.5 to 4 inches from the top to prevent this. If you are only making a few frames, make the end bars straight and use screws, screweyes, staples or nails to get the bee space. A screweye in the top bar and one in the lower part of the end bar facing away from you on the right and the same facing toward you on the left and you have your bee space.
If you do very many homemade frames then removing wood like the standard frame would be very much faster than the above. The nice thing about the screweyes is the small area that is propolized.
38 years - 25 colonies, 32 Nucs - IPM disciple - Naturally Skeptic