how to make a window sash

" deeper than the length of the tenons. Nail the fillet to the bottom of the 1x6 to complete the head or and window casing assembly. To this number (12"), add the length of two tenons (1-1⁄4 This set is Freud’s 99-050 and 99-051 pairing. With the overall dimensions of the window set, all of the individual pieces of the window can be sized and cut to length. Become a member and get instant access to thousands of videos, how-tos, tool reviews, and design features. You make two equal thickness layers that combined will equal the overall thickness of the sash rail. The instructions that follow are for simple sash. "-thick stock, they come with sturdy 1⁄2 " long later.). Straight-grain, knot-free wood is essential because the thin, narrow muntins need to be as strong and stable as possible. Place wedges under the front of the sill, and then screw the sill to the sides, with the wedges tilting the sill toward the exterior. I loved it so much that I want to share it with my readers! All set? " shanks. Chairmaker Caleb James shared this amazing video on how skilled joiners used to construct sash windows. These quartersawn lengths of wood are less liable to warp and twist. " (for the coped joint). Make multiple cuts with the dado set 5⁄8 If you have to make meeting rails like this, the joinery is the same, except that the stiles are tenoned and the rail is sized to overlap (with bevel or rabbet) the other rail. The second in our complex router bit series is the Window Sash bit set. Get home building tips, offers, and expert advice in your inbox. Here I’ll describe how I made double-hung sash for jambs that don’t have parting strips or weather stops. If I did, my shop rates would be higher. Add glue and screw the frame together with 2-inch screws to build a pocket frame. On a historic-restoration project I worked on not long ago, the house’s window sash were in poor shape. " past the tenon shoulder, cut both ends of the rails, sash bar, and muntins. Sash are normally 1 3/8 inches thick and wood combination storm and screen windows are usually 11/8 inches thick. ") and 1⁄2 Using a table saw, cut a 1/8″ wide x ¼” deep groove, 3/8″ from the inside edge of all four pieces. All Rights Reserved. However, I find that working through the detail design in SketchUp clears up any uncertainty in the construction of these complex joints. Smooth the compound with a putty knife, making a 30- to 45-degree angle from the glass out to the front surface of the sash frame. To figure rail length, subtract the combined width of the stiles (6") from the finished width of the window (18"). A ranch-type house may provide the best appearance with top and bottom sash … But before the window work started, the owner decided to have new sash right off. Making Window Sash How to do a custom job with ordinary shop tools and a router by John Leeke 0 n a historic-restoration project I worked on not long ago, the house's window sash were in poor shape. Position the saw's fence 1-1⁄4 (Plan to cut 1-1⁄4 - M.K. The rails and stiles measure 2-1/4" wide x 1-3/8" thick. Let's go through the easy steps in using this bit. Sash windows traditionally consist of a … Also mark the outside edges of the rails and stiles, and place marks centered on the rails and stiles where they intersect with the muntins and sash bar and on the sash bar where it intersects with the muntins. Here's how to calculate the lengths of your parts, using an 18X24" window with 3"-wide rails and stiles as an example. The window has four panes and the muntins appear to be two pieces joined in the center. One had been without paint for many years, so its joints came apart easily. The mortise in the sash bar will go completely through it. Mount the glass in place with glazing points and glazing putty, or with quarter-round strips of wood mitered on their ends and nailed down (see the Glass Stop Detail drawing - first illustration above). Cut the sash bars and muntins 3⁄4 10 Mold both edges of the sash bar and muntins. Your tenons should be 1⁄4 1 Cut your stiles, rails, sash bars, and muntins to width and length from 1-3⁄8 Source: www.arnoldzlotofftoolmuseum.com The beautiful traditional art of joinery, brought to life in the construction of a sash window frame from […] Lately I came across two such planes, used to make the sash bars on a classic 3X2 single or double hung windows. You can avoid this trouble altogether, if you wish, by applying the weather stops (with brads and waterproof glue) after the sash are assembled. When fitting replacement sash windows in an older property, or choosing new sash windows for a period-style self-build, it is crucial to get the time period right. Not too bad for short-order work that met my specific requirements exactly. If you make more than one window or door you may want to set up a router table with a straight bit to do this more quickly. 3 To cut 1-1⁄4 Synopsis: While renovating an old house, the author decides to make window sash to match the originals. Meeting rails with weather stops are thicker in section and narrower in elevation than ordinary rails, and are mortised to receive tenons on the stiles, rather than the other way around. By John Leeke Issue 18. Here's how … hp or more mounted in a table. Sash may be divided into a number of lights by small wood members called muntins. Place the face side of a rail on the table and adjust the coping bit up so the tops of its cutters contact the tenon. Window sash sets consist of two bits like those above. All I had to do was see how it was made, and reproduce each part. If you're attaching the four pieces directly to the rough framing, drill pilot holes with a 3/16-inch bit, centered through each piece, and screw the top on first. In this episode of Shop Class, learn how to measure, cut, and build window casing made of cellular PVC, solid wood, poly-ash boards, or any common molding material. "-high cut. 4 Position the rail, sash bar, or muntin face side up on the tablesaw. A sidebar covers installation. Roll glazing compound into a rope and apply around the entire pane glass. Oct 3, 2017 - We shed some light on how to use these tricky bits. " from the cutter tip with the tip rotated to its farthest distance from the fence.). 6 Install the coping bit in your router table. "-thick stock, and position it so the sash bar and muntins slide snugly between it and the main fence. Plus, get tips for a clean and solid installation. Step 1 Capture the Profile Photo by Wendell T. Webber. If the problem is a painted-over joint, it's best to cut it, either with a window zipper (a serrated-blade … With them you can make traditionally styled rail-and-stile frames with coped joints and a rabbeted side for accepting glass. The timber sash typically measures 32mm or 1-1/4″. For safety and good results, use them with a router rated at 1-1⁄2 The production time for the kind of sash described here on a short run of three or four double units is almost six hours per unit. For bare wood, rub on protective beeswax. I try to use all heartwood, which is stronger and more rot resistant. 2 Mark the face side of your workpieces (the inside surface of your window or the most-viewed side of your door). Synopsis: While renovating an old house, the author decides to make window sash to match the originals. I use white pine for all my sash because it strikes a good balance between machinability and durability. Each pane should be 1⁄8 The first step to making a window is to determine the outside dimension of the sash and cut the rails and stiles to size. Use pushsticks to pass the stock between the fences. 7 Mark the positions of the mortises on the stiles by using the tenon that mates with it. It takes me about hours for all the setups needed during a run of sash. Press a profile gauge against an intact muntin section and the glass, as shown. Making Window Sash How to do a custom job with ordinary shop tools and a router. Make the cut in multiple passes as shown below. You can also make the narrow sash bars and muntins for holding multiple panes of glass (our window below shows four panes, but your window or door may have many more depending on its size). I was going to make the muntins using the table saw for the rabbets and rout the detail. On painted sashes, guard against toxic lead by sealing the finish under clear… Use the same steps to mark the position of the mortises that hold the sash bar and muntin tenons. "-long tenons on both ends of the sash bar and muntins; you'll trim the muntin tenons that intersect with the sash bars to 1⁄8 With the face side down, mold the inside edges of the rails and stiles. Get complete site access to expert advice, how-to videos, Code Check, and more, plus the print magazine. " + 1-1⁄4 This is usually when the damage extends beyond the window or when the sash is a type that is meant to be fixed in place (not merely a window sash that is stuck in place due to paint or expansion). "I have learned so much thanks to the searchable articles on the FHB website. Place a 1⁄8 Many manufacturers make sash bits, but most are designed as ‘stub’ tenon bits, working more like a stile and rail door set. " smaller in width and length than the rabbeted opening it fits into. © 2021 Meredith Corporation. Cut the 1x6 to length. Sash making October 7, 2020 pfollansbee Uncategorized joinery , mortise and tenon joinery , Sash making , window sash Quite some time ago, my friend Rick DeWolf posted a window he’d made for his barn. Make this fence from 1-1⁄4 Then cut the fillet 3/4 in. (Possibly reduced because of our more temperate climate). The original plan for the sash was to repair the worst of them and then replace them all sometime in the future. Now's a good time to trim the muntin tenons that intersect the sash bar. For more related content, subscribe to our newsletter! Mark and drill three pilot holes, spaced evenly through the ends of the top and sill pieces at each joint using a drill/driver. "-thick stock. I’d rather keep my capital expenses low and have more hourly income. While wooden sash windows look absolutely beautiful, they really are high maintenance. To maintain these dimensions, I have found it possible to reposition the bearing on CMT’s sash window bit, which normally requires a sash thickness of at least 35mm or 1-3/8″. In some cases, you'll need to replace the whole window or have a window company or contractor to come in to make extensive repairs. " from the side of the dado set farthest from the fence. The 55-802 Window Sash Jr. router bit set allows you to make a thinner sash but requires a different procedure for creating the tenons. He has only a small shop and no specialized tools, but he finds a way to produce traditional wood sash with tools he has on hand. The original plan for the sash was to repair the worst of them and then replace them all sometime in the future. Classic window sash and breakfront glass doors with molded muntins are challenging woodworking projects. 12 Install the glass in the rabbeted openings on the back face of the door or window. Considering my time and the cost of materials, the final price was about 20% higher than ordering custom-made sash from the local lumberyard. Stray even a bit when installing shelf standards, and your shelves will rock maddeningly.... read more. " tenons on both ends of the rails, sash bars, and muntins, install a full-width dado set in your tablesaw, and adjust it for a 5⁄8 With sash removed, the casing is just a frame. Then, rest the rail on top of the stile, as shown below, to mark the mortise width. Use a fine-toothed saw to remove the small amount of material on the outside end of each stile mortise, as shown below, and in the illustration  in the Stile Detail drawing (first illustration above). Make a Matching Window Screen Make your own screens, using lightweight 1×3 boards (preferably red cedar). A lot of people have asked if it is possible to make 1-1/8" to 1-1/4" thick window sash for restoration projects or even storm windows. Would you explain to me how the muntins are joined together and attached to the sash? He has only a small shop and no specialized tools, but he finds a way to produce traditional wood sash with tools he has on hand. On the inside, frost and condensation lead them to quickly build up black mould in the corners; while the paint often shrivels and peels between the wood frame and the glass panes. However, many older sash are made for jambs that have parting strips, and so require meeting rails with weather stops. Below I will show how I go about designing a window sash. Cut them to 1⁄8 8 Install the profile bit in your router table, and adjust it as shown below. "-long tenon, set the fence 1-1⁄2 Cut your stiles, rails, sash bars, and muntins to width and length from 1-3⁄8 "-thick stock. I didn’t have enough time to place an order with a custom millworks; so I decided to make the sash in my own small shop, even though it lacks specialized sash-making machinery. longer than the 1x6. Both layers are segmented construction with one layer being made with all the same length segments and the other having one segment cut in half with the short pieces located at the two ends. Check for square again before the glue sets up. Cut four pieces of 1×3 to fit the opening. The Cornerstones of Comfort: How To Choose the Right Windows and Doors for Your Climate, Plus, get an extra 20% off with code GIFT20, Podcast 235: Residential Architecture, Rusty Cars, and Ruined Floor Joists, Podcast 195: Replacing Porch Flooring, Creating Comfortable Spaces, and the Right Trim for an Alaskan Ranch, Double-Stud Walls and Insulated Window Bucks, Simple Way to Make Old Walls Straight and Plumb, Expert insights on techniques and principles. These comprise the outer framework that holds the glass panes in place known as stiles. All of the coped joints are reinforced with tenons for long-lasting durability. Start your subscription today and save up to 52%. " thick. The window has sash—the framed glazing that make up the moving parts—and the casing, which is fixed trim. The gauge’s metal wires slide to create both a positive and a negative replica of the muntin’s profile, which can then be used to make a molding template. Disassemble, apply glue to all mating surfaces, and clamp. Scrollsaw, Carving, and Decorative Projects, Wood Joint Torture Test 2 Doors & Drawers, Gauge blocks for faster rail-and-stile setup, A starting block sets shelf standards straight. So what did you think? (For a 1-1⁄4 " high as before. This meant I’d have to match the joinery and molding profile of the originals, and I’d have to work quickly enough to make money on the job without overcharging my customer. Sashes are the movable parts of the window that give it its distinct name. You want to paint the casing or trim one color (the main exterior trim color), and the sash a different color or value. Place the workpiece on the tablesaw face down with one edge against a miter gauge and one end against the fence. Specialist Tools for Sash Window Making From its first appearance towards the end of the 17th century right up to the present day, sash windows have been used in every sort of building.1 A walk round any British village, town or city makes clear the quantity of sash windows that have been manufactured over the last three centuries. With the fence adjusted so the coping bit cuts 1⁄4 The old sash were hand-made over 150 years ago. IBSx Roundtable: Behind the Siding—WRB, Drainable WRB, or Rainscreen? The challenge was to keep track of all those parts, and to make the joints fit properly so the sash would get as much rigidity from its mechanical integrity as from the glue in the joints. The panes on their part are vertically separated from one another by molded pieces of wood called sash bars, and horizontally by muntins. © 2021 The Taunton Press, Inc. All rights reserved. Also, the outer frame can twist if it’s made from wood with unruly grain. For more photos, illustrations, and details, click the View PDF button below: Sign up for eletters today and get the latest how-to from Fine Homebuilding, plus special offers. For more information, visit http://edinburghsashandcase.co.uk I can confidently say that I expect to be a life-long subscriber." " long. 5 Complete the tenon cuts on the rails by placing them outside edge down on the tablesaw. Allow the compound to harden overnight and the new sash is ready to be painted or stained. First, cut the stiles to the full height of the window (24"). It’s best to cut all the rails and stiles from parts of the board that have vertical grain. So, for our example we cut the rails 15" long. 11 Assemble the project without glue to check for fit and squareness. There are a few specialised planes to make windows, the ones I found are called Adjustable Sash planes (an American invention I believed), since the space between the decorative cut and the glass rabbet is variable, adjusted by screwing or unscrewing the two part of the body apart. " spacer between the workpiece and tablesaw top as shown below, and make the same cut as described in the previous step. " wide and calculate their lengths as you did the rails. Fine Homebuilding hosts a panel of building pros in a discussion of the various types of high-quality substrates that can be installed under siding to make a wall assembly more durable. If you've considered making your own custom windows or french doors, but thought the task was a little too involved, here's a bit set that helps you get great results without a lot of fuss. Cut the mortises 3⁄8 We shed some light on how to use these tricky bits. 9 To perform the same operation on the sash bar and muntins, clamp a secondary fence onto the router table, as shown below. Because you will plow these bits through 1-3⁄8 Start by setting the 1x6 on top of the side casings and marking it at the outside edge of each casing. First, as shown below, stand the stile inside edge up on a work surface, and position the rail to mark the length of the mortise. Of course, I could lower these time figures by keeping specialized machinery set up for sash work. There were several developments and style changes over the years. The overall size of my window is 18" x 24".

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