My aging mother lives out of state in a house my parents built in 1953. I try to help with repairs and the most recent project involved rot in the outside of some window sills. These are wooden double-hung (Andersen) windows. The cause was most likely due to aluminum storms being caulked so there was no drainage. I have a decent wood-shop in my home, but only a few hand tools I am able to transport to my mom’s house.
This past weekend, I replaced the outer half of a sill. The job came out well, but could have been easier if I had a better way of cleanly cutting the old sill off. The cut needed to be between the jambs. I used a skill saw for the center portion, but the saw frame limited my cut. I had to chisel 3 1/2″ on either end. The sill is made from 2x stock, so chiseling a clean edge was difficult and time consuming. Since there are more windows needing this treatment, I’m wondering if there is a tool or method I’m overlooking. Something that can make a zero clearance cut at a controlled depth.
I would like to manufacture some replacement sill blanks in my shop, then bring them down and fit them. This would work best if I could reliably make a clean accurate cut between the jambs. Any suggestions appreciated.
BTW, replacement windows are not a realistic option for cost and aesthetics.
Replies
A MultiMaster (or MM clone) would probably do the job. Just about any job you do with a wood chisel can be done with a MM.
Look at the Fein Multimaster for the cuts you need to make.
There are lesser cost units from PC, Bosch and Dremel...........Harbor Freight also.
I've done many rot repairs and the multimaster took it from cutting out to final sanding.
Best of luck.
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Tommy,
I'm down in Southern VT and yes I replace a lot of sills. I usually use a jig saw and when I get close to the jambs slowly raise the front of it so the blade continues to cut closer to the jamb. And yes a sharp chisel finishes it. As for the perfect tool, I'm wondering if one of those Fein multi-master tools would do it?
Good luck,
Mark
i have never had that great of luck replacing jut the "nose" of the sill. if thats what your doing i have seen pieces you can buy made in aztec type pvc material. you might look at the harbor frieght multi tool to cut it off.
i try and get the whole sill out and replace. a recip saw and lots of cussing will get them out.try and get a least a 3" pc out whole to use for a template to make a new one. i am in a project now with about 15 sills to replace. i'm using aztec and feel it will work out really well and last a lot longer than the wood. you can buy premade wood sill at the lumberyard,but it's fingerjointed together.
another option is to leave it and wrap it with metal.
heres the tool.
http://www.harborfreight.com/cpi/ctaf/displayitem.taf?itemnumber=67256
the older i get ,
the more people tick me off
As others have said, a multimaster (or one of the knock-offs) will make the cut you're talking about.
But when I need to replace any exterior sill beyond the sillnosing, I cut out the entire sill.
Of course, this involves removing some of the interior trim, then using a sawzall to cut the nails that go up thru the sill into the jambs. Then the nails going down thru the sill into framing.
I then use the PVC sill and nosing replacement pieces. Once installed and painted, they look like wood. And they will never rot.
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And I can't question how or when or why when I'm gone;
I can't live proud enough to die when I'm gone,
So I guess I'll have to do it while I'm here. (Phil Ochs)
Wow, the MultiMaster (or a clone) looks like exactly what I need, thanks.I would agree that replacing the entire sill would be a better long term option, but it's way more involved than I am prepared to go.
Edited 9/9/2009 9:18 am ET by Tommymc
The only real problem with the MM is that it's a little hard to handle -- takes an exceptionally steady hand to get a clean, straight cut over some distance, and it's fairly easy to bung up finished surfaces if it gets away from you a little.But in this scenario it should work fine, though you might want to leave a little "fat" to clean up with a chisel afterwards.
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