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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). Classic window sash and breakfront glass doors with molded muntins are challenging woodworking projects. 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. "-high cut. With the fence adjusted so the coping bit cuts 1⁄4 11 Assemble the project without glue to check for fit and squareness. The first step to making a window is to determine the outside dimension of the sash and cut the rails and stiles to size. 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. This set is Freud’s 99-050 and 99-051 pairing. I was going to make the muntins using the table saw for the rabbets and rout the detail. We shed some light on how to use these tricky bits. 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. Here's how … 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. Your tenons should be 1⁄4 For bare wood, rub on protective beeswax. "-long tenon, set the fence 1-1⁄2 With the overall dimensions of the window set, all of the individual pieces of the window can be sized and cut to length. However, many older sash are made for jambs that have parting strips, and so require meeting rails with weather stops. Synopsis: While renovating an old house, the author decides to make window sash to match the originals. " wide and calculate their lengths as you did the rails. Use pushsticks to pass the stock between the fences. 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. Start by setting the 1x6 on top of the side casings and marking it at the outside edge of each casing. 3 To cut 1-1⁄4 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. 9 To perform the same operation on the sash bar and muntins, clamp a secondary fence onto the router table, as shown below. All set? 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. Allow the compound to harden overnight and the new sash is ready to be painted or stained. longer than the 1x6. The rails and stiles measure 2-1/4" wide x 1-3/8" thick. 6 Install the coping bit in your router table. So what did you think? The original plan for the sash was to repair the worst of them and then replace them all sometime in the future. 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. 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. Make the cut in multiple passes as shown below. I use white pine for all my sash because it strikes a good balance between machinability and durability. Then cut the fillet 3/4 in. These quartersawn lengths of wood are less liable to warp and twist. But before the window work started, the owner decided to have new sash right off. For more related content, subscribe to our newsletter! 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. All Rights Reserved. 10 Mold both edges of the sash bar and muntins. hp or more mounted in a table. Stray even a bit when installing shelf standards, and your shelves will rock maddeningly.... read more. "I have learned so much thanks to the searchable articles on the FHB website. 8 Install the profile bit in your router table, and adjust it as shown below. Step 1 Capture the Profile Photo by Wendell T. Webber. © 2021 The Taunton Press, Inc. All rights reserved. Oct 3, 2017 - We shed some light on how to use these tricky bits. Place the workpiece on the tablesaw face down with one edge against a miter gauge and one end against the fence. 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). 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. There were several developments and style changes over the years. The window has sash—the framed glazing that make up the moving parts—and the casing, which is fixed trim. Straight-grain, knot-free wood is essential because the thin, narrow muntins need to be as strong and stable as possible. For safety and good results, use them with a router rated at 1-1⁄2 Cut the 1x6 to length. With the face side down, mold the inside edges of the rails and stiles. You make two equal thickness layers that combined will equal the overall thickness of the sash rail. 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. If I did, my shop rates would be higher. "-thick stock, they come with sturdy 1⁄2 Sash may be divided into a number of lights by small wood members called muntins. Plus, get tips for a clean and solid installation. " past the tenon shoulder, cut both ends of the rails, sash bar, and muntins. 12 Install the glass in the rabbeted openings on the back face of the door or window. Position the saw's fence 1-1⁄4 The second in our complex router bit series is the Window Sash bit set. A ranch-type house may provide the best appearance with top and bottom sash … 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. Cut them to 1⁄8 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 panes on their part are vertically separated from one another by molded pieces of wood called sash bars, and horizontally by muntins. Sashes are the movable parts of the window that give it its distinct name. Here's how to calculate the lengths of your parts, using an 18X24" window with 3"-wide rails and stiles as an example. 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. All I had to do was see how it was made, and reproduce each part. Press a profile gauge against an intact muntin section and the glass, as shown. 7 Mark the positions of the mortises on the stiles by using the tenon that mates with it. Roll glazing compound into a rope and apply around the entire pane glass. Mark and drill three pilot holes, spaced evenly through the ends of the top and sill pieces at each joint using a drill/driver. 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. I can confidently say that I expect to be a life-long subscriber." 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.

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