A Small Peek Into Modern Manufacturing Processes For Wooden Sash Windows

The sash window design was invented by English scientist Robert Hooke

. The oldest sash windows date back to the seventeenth century. This window style is classic and is normally found on Georgian and Victorian style homes. However, many contractors still apply this design on modern buildings and homes in the twenty first century. Precise instructions catered more toward personal preference can be located, but here is a quick look at modern manufacturing processes for wooden sash windows.

A window created in this design is made up of glass panes, otherwise known as sashes, that are movable. A typical window is comprised of two panes. In its original design, each sash is sectioned into three panels wide and two panels deep. This creates one large window with six panels on each pane. Traditionally, one of the sashes moves either vertically or horizontally. Some windows are designed with both having the same amount of mobility. When one or both of the sashes are moved, ventilation is created and is able to circulate air in and out of a room.

Some essential tools are needed in order to construct a wooden sash window. Obviously, wood is the main ingredient. To cut the wood, make sure you have a table saw complete with a dado blade and a finishing blade. These blades will ensure the wood is cut precisely to your measurements. Additional items are wood glue, a rabbeting bit, sandpaper and wood glue. You should use safety goggles to protect your eyes from wood shavings. A quarter in chisel will also be needed to square off edges of the wood.

The first thing you need to do is build the frame. Four pieces of wood are needed for a sash. The side pieces will be the same dimensions as each other. Many times, the top and bottom pieces differ in size. At each end of both top and bottom wood pieces, use the dado blade to create tenons. Then, cut holes of the same dimensions into the side pieces. The tenons will fit perfectly into the holes and secured with wood glue. The glue will take at least one hour to properly dry. Once the glue is dry, nail the side pieces to the top and bottom pieces to keep them adjoined.

Now that the frame is sturdy, a rabbet, or notch, needs to be cut along the inside of the frame where the glass is going to be secured for the window. A rabbeting bit and quarter inch chisel will help ensure the rabbet is even throughout the frame. Before placing the glass into the rabbet, spread a glazing compound into the entire rabbet. A small string dipped in the glaze and then placed into the notch will help apply the substance. Lay the glass in the rabbet and push it down to make sure it sticks to the glaze. Add some more glaze to the edge of the glass to secure it in. Allow the glaze to dry overnight. Once the glaze has stiffened, the window is ready to be stained or painted.

Hot and cold weather will make the wood of the frame expand and shrink. Rainwater and humidity will allow the wood to mold or rot, which will weaken the wood strength. Even the sliding factor of the sash window will wear the wood out. You cannot avoid weather erosion. However, to restore a wooden sash, just follow the same procedures and make a new wooden sash frame.

The cost benefit of pursuing this handyman project on your own is that you avoid having to pay for labor. However, you still have to invest enough money into the right materials to build a strong window sash. Since this is a somewhat challenging and time-consuming project, you might opt to have a professional build a window to your personal liking. There are many carpenters or builders that specialize in making sash windows and can be found on the Internet or in the phone book.

by: Charlotte Buckley

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