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Showcase cover image for Window replaced with hand tool made version.

Project Information

It all started with a neighbor that was frustrated with lead time and cost to replace one window. We are both in a historic preservation district so I looked at it and said "I can build that". In reality I had no idea if I could but for some reason I enjoy forcing myself beyond my comfort zone.. I started with the Lost Art Press book Doormaking and Window-Making and watched every video I could find on traditional hand tool window making.

I laid out a story stick and started milling stock. More than once I would wake up at 3:00 AM and think "I screwed this up" I would check the next day and find I was still good. I did a test fit and made some miner adjustments before priming and installing glass. I used no glue and pegged the joints. I was surprised at how rigid the two sashes became when complete. Yesterday I installed the new hand made sashes complete with new pulleys to replace the one bashed out for the replacement unit that had rotted out. I had perfect fit at the meeting rails and both sashes travel effortlessly. He is very pleased and honestly surprised at how well it fit, (me too).

Once again I improved my skill set and although it was after I had substantially completed this window I decided to take a window making class at the WoodWright school with Roy Underhill. I am currently cutting mortises in my forth window build as I try to commit this to memory. Thanks for checking this out!

Gallery

Comments

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6,917 Posts
CF, nicely done, looks like you have a good fit there with the frames and the cover edge. Congrats on a job well done.
 

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28,280 Posts
Good looking window. Nice work on it!!

Cheers, Jim
 

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4,765 Posts
impressive. Big undertaking for sure. Looks great. Well done.
 

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5,383 Posts
Purity darn nice! I love my story sticks:)
 

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2,012 Posts
Very fine job. Only 15 more to go now!
 

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4,235 Posts
Very fine job. Only 15 more to go now!

- JCamp
I laugh, my house has 14 windows. The top sash has 9 lights so it is a bit more involved.
 

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7,538 Posts
Always impressed with those who can successfully repair/replace old woodwork. Nothing is ever as simple as it may first appear, out of square, etc.

Nice accomplishment!
 

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11,003 Posts
Very nice, CF! I'm thinking I need new doors on my shop one of these years (they built it with doors that open in, which means with any small misalignment, and a strong east wind during a rain, I get water in the shop), and I hope they go half as smoothly as your window did.
 

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8,109 Posts
That is some impressive work. Sweet looking plane too.
 

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Funny side note, I found two weights in one side via the trap door in the jamb so I assumed the other side would be the same. But no, they were gone. He thought about it for a minute and went under the house and returned with two more weights. Thank you all for the kind comments.
 
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