Making Window Sash
How to do a custom job with ordinary shop tools and a router.
Synopsis: While renovating an old house, the author decides to make window sash to match the originals. 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. A sidebar covers installation.
On a historic-restoration project I worked on not long ago, the house’s window sash were in poor shape. The original plan for the sash was to repair the worst of them and then replace them all sometime in the future. But before the window work started, the owner decided to have new sash right off. 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. This meant I’d have to match the joinery and molding profile of the originals, and I’d…