Project builds #66: Starting a run of new sashes

So it would seem I’m becoming some what of an area expert on the sash window. I have taken on another two small arch top sash windows, they are of Victorian style but are going to be double glazed with plant on beads. Lots of lead weight required (I’m toying with making a mould to make my own lead weight bars.).

I have local carpenters asking for prices and one local joiner wants me to take all his sash enquiries on as he finds them to complicated.

The current pair I’m making are for the Georgian house that I have done all the restoration work on. Having done a lot of resto work I have various of cut bits that I have taken out of the old windows that I can now use as patterns for these new ones.

When matching a section of meeting rail I noticed the original lay out lines are still there as visible today as they were when the crafts man made the window some 170-300 years ago. Clear concise knife lines made with a single stroke of a sharp knife.

Interestingly I still lay out a lot with knife lines, thanks to the advance in pencil technology though I do mark some layout marks and face Marks etc in pencil.

It gives a strong connection to the previous craftsman and I’m proud to be making the windows that are exacting copies of their work I hope to last another 200 years maybe.

Tags: sash windows history professional woodworking

Dreaming of a sawmill, feels like a museum. Thanks for looking Adam.

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Madts ...

Cool stuff.


Whitacrebespoke ...

Certainly is

lightweightladylefty ...


We admire your work! Could you recycle the lead weights from the original windows? Or are you using a heavier wood?


Whitacrebespoke ...

The old windows are fitted with cast ironweights and so far on the restore work they have been 1-2kg per light under weight so I have had to add more weight in the form of lead wrapped around the cord.

I think on this occasion I will buy new steel weights. That then gives me a set of cast weights in stock to use on other jobs.

I’m constructing the new windows in Douglas fir which is slightly heavier than the original timber as the stock I have is very dense grain. Even so though the current weights are still under the weight required with all original timber.

The problem has evolved from them being messed with I think. The few remaining original panes were extremely thin probably 2-2.5mm the new stuff is 3mm. A lot of them had 4-5&6mm glass in them

Thankyou for admiring my work, it’s just day to day for me.

lightweightladylefty ...

Thanks for your explanation Whitacre.