sash window horns

[flanajb]

Does anyone have any tricks for cutting sash window horns. Of the whole sash manufacturing process I do find it one of the most time consuming aspects to get right.

Not having a bandsaw to hand makes things even harder

 

[Mattty]

Does anyone have any tricks for cutting sash window horns. Of the whole sash manufacturing process I do find it one of the most time consuming aspects to get right.

Not having a bandsaw to hand makes things even harder

Many moons ago when i was an apprentice my boss used to clamp a job lot of sash sides together and then pass them over the spindle moulder stood on end- the results where very good! It's certainly not the done thing these days and not something i'd reccomend doing.. :shock:

Edit- i would ask the q here- http://www.woodworkuk.co.uk/forum/index.php
There is a number of Joiners on there who regularly make sash windows.

 

[woodguy7]

An mdf template, jigsaw & a router with bearing profile cutter works just fine. Everyone comes out the same.

Woodguy

 

[woodsworth]

I just cut some this week on the band saw and clamped them together and sanded them with the belt sander and then finished them up with hand sand paper. I checked every so often by moving the order so that i was sanding level. Seemed to work and only took about 45 minutes. There were only four windows though.

 

[flanajb]

I did think about making a profile and using a flutted bearing cutter, but I suspect you need a small diameter cutter for it ti work ?

 

[woodguy7]

About a half inch cutter will be as small as i would go. You will need some hand work for sharp internal corners i'm afraid but not that difficult.

Woodguy.

 

[JoinerySolutions]

I did think about making a profile and using a flutted bearing cutter, but I suspect you need a small diameter cutter for it ti work ?

If you don't have the required size of bearing guided cutter use a straght cutter, guide bush and a template that is smaller than required by the offset of the guide bush. I have done them by hand with a coping saw and chisel with plenty of sanding in the past but it is a bit tedious
If the profile has too small an inner curvature drill that part first with a forstner bit then cut or route to it.

 

[mr grimsdale]

I'd draw with 2H pencil, the profile on both sides, from a template. Remove as much waste as possible with tenon saw and chisel (cut and split). Finish as close as poss with paring chisel cuts across the grain, then sand paper or rasp etc.
Quicker than it sounds once you get going.

 

[markymark12]

I will confess to ganging them all up with a sash cramp, stood up and passing over the spindle with a push block.. It is the way i was shown many moons ago and by far the quickest means. It takes longer to put the block in than carry out.

Must remember i am no longer allowed :wink: and i need to add in money on jobs so i can bugger about with each one.