I know every one can’t use a shaper or router to make up simple DH sash from scratch, so I thought I’d show a simple way that avoids all the cope cuts.
I make up the frame to size and biscut the butt joints and TB3 otr similar glue. Plenty strong for average size sash. I then rip or plane 1/4″ thick muntin and mullions , half lapped at the cross, and let into the frame 1/4″.
Mill the internal stop ( any profile can be made, this one happens to be a flat bevel @ 12 degrees) from a suitable clear wood, poplar in this case. 5 passes on the table saw to get 2 lengths of profiled stop, on edge, one pass on each face at 12* and then set the fence to 1/4” and while on edge still, rip out the center waste of about 1/4″ ( a dado would work, but I do it all with one blade), then lay the board flat and set the fennce at 5/8″ ( this varies with frame thickness and glass thickness) and rip off the two stops..use a push stick.
Ok I fess up, to save time, I mill a BUNCH at once and use 3 table saws,one for 12*, one for the center waste, and one for the final width..I’m lazy and changing fence and blade heights is tedious..LOL I also do BOTH edges of a wide board, to get as many pcs as I can safely.
Miter the stops and small bead of glue, and then pin with a 3/8th” 23 ga. pins.
Thats that side.
Now take a hunk of azek that is 3/4″ thick, rip it t 5/8″, set a table or band saw at 30* and with the 5/8th thickness up and down, rip off a triangle from 1/4″ ( the glass rabbet created) to zero..you get two as well by swapping end for end ( I have started using the bandsaw for this , it is less likely to get chewed by the blade if it flops into it inadvertantly).
Here is the finished cross section of a mullion.View Image
The glass is bedded in a bead of Big Stretch caulk, and the back of the azek gets a slight bead as well, SS, pins for attaching.
Once painted, these azek stops far surpass putty for many reasons, it wont crack, and can be pried out much easier to replace a pane of glass.
Spheramid Enterprises Architectural Woodworks
Repairs, Remodeling, Restorations