Building Your Own Window Sashes

Making barn sash style windows with a router bit set.

Building your own window sashes. 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. The timber sash typically measures 32mm or 1 1 4. I have wood windows in my house and for a bunch of reason i don t want to buy new windows but would like to upgrade my current windows with todays technology and maybe triple pane glass. Window sash sets consist of two bits like those above.

Mark and drill three pilot holes spaced evenly through the ends of the top and sill pieces at each joint using a drill driver. Looking for information and details on how to build your own box sash windows. Careful measurements and precision cutting are the second key to a well made sash. A dado blade cuts a wider opening than a regular blade.

These are small custom windows intended for a chicken coop. The tenons should be 1 4 thick when using the infinity 55 801 window sash set. 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. So i decided to make the sash in my own small shop even though it lacks specialized sashmaking machinery.

Building your own window sash. Possibly reduced because of our more temperate climate. Stiles rails and muntins are molded on both sides of the single strength glass 2 5 mm thick there is a small bead of clear latex silicone caulking where the glass meets the wood on the outside of the window to make them weathertight. Add glue and screw the frame together with 2 inch screws to build a pocket frame.

I might even publish complete plans when i ve proved the design. But before the window work started the owner decided to have new sash right off. Comment and let me know if you d like any specific details or you can think of easier. Sashes are screwed together with zinc plated screws.

The sashes are true divided lites. Set your dado blade height and width to match the requirements of the tenon. Make the template square and the proper size and the finished product will be a square usable window sash. The router bit set used for this project is.

Sash was to repair the worst of them and then replace them all sometime in the future. Also to make things easy i will refer to the side of the window with the profile as the front or face and the side of the window with the rabbets for the glass as the back. I ll be recording the build of my first window and attempting to give some useful details. With them you can make traditionally styled rail and stile frames with coped joints and a rabbeted side for accepting glass.