softtop
Established Member
I have to make six windows for my house. Four are replacements, two are new but all are a similar style. There is only one original one left (completely rotten) but I am trying to copy it as closely as possible.
This leads to a selection of new techniques for me but I hope you may be interested to see how I've been getting on.
The timber is all Dougie Fir (over 0.5 cubic metres of it) plus oak for the cills.
The original window frame has open mortice/tenons with pegs and the window has through tenons (with shoulders), also pegged, plus wedges on the top and bottom of the glazing bars. Hence this is what I'm trying to do. (Can't promise not to get the Domino out for the other ones though!).
Any comments gratefully received.
First of all I have the oak for the cill:
...which I plane two sides straight on the P/T:
...then cut the profile on the bandsaw:
...then over to the router table to get the flat section for the window to sit on:
Finally I route a drip groove in the bottom.
I spent the whole bank holiday weekend cutting, planing, thicknessing and then putting mouldings onto a load of timber for the windows:
...and making glazing bars:
So I cut a mortice in the cill and tenon onto the frame:
I bought a mortice machine from the bay which I reckoned was a bit of a luxury purchase, but having tried cutting them by hand it took me ages and the results were somewhat rough so I'm pleased I did so. I've been sawing the tenons on the bandsaw, which has worked quite well.
Next I make some dowels out of oak:
...and cut the holes in the mortice and tenons, remembering to move the holes in the tenon 1.5mm out to allow the dowel to pull the joint tight:
I am greatly indebted to the video on Youtube from Chris Schwarz showing how to do the drawbore stuff.
Next I glue up and bash in the pegs and then clamp for good measure:
This particular window has an additional timber support on the top (complete with drip) which I have slotted onto the protruding tenons:
Now onto the window frame. I've forgotten to take a photo but I've cut out the mortice and tenons on the top and side rails. Now I need to add in the glazing bars, so more morticing and then shaping the rails to fit:
...and they do:
Dry fit to work out where the middle glazing bars will go:
I cut them out to fit as well (tricky business getting them to meet up in the middle!) and then make some more oak pegs and drill out the mortices:
... and tenons:
...before putting it all together with the glue, bashing in the pegs, checking it's square and clamping up:
Here is a pegged joint:
...and finally adding the wedges in to the top and bottom of the middle glazing bar:
Don't know if a lot of this is overkill, and I could certainly have done it a lot faster without so many traditional techniques. Also there are a few rough edges but it will all be getting painted so noone will ever know...
Now I need to consider how I will do the next five.
Thanks for looking,
Henry
This leads to a selection of new techniques for me but I hope you may be interested to see how I've been getting on.
The timber is all Dougie Fir (over 0.5 cubic metres of it) plus oak for the cills.
The original window frame has open mortice/tenons with pegs and the window has through tenons (with shoulders), also pegged, plus wedges on the top and bottom of the glazing bars. Hence this is what I'm trying to do. (Can't promise not to get the Domino out for the other ones though!).
Any comments gratefully received.
First of all I have the oak for the cill:
...which I plane two sides straight on the P/T:
...then cut the profile on the bandsaw:
...then over to the router table to get the flat section for the window to sit on:
Finally I route a drip groove in the bottom.
I spent the whole bank holiday weekend cutting, planing, thicknessing and then putting mouldings onto a load of timber for the windows:
...and making glazing bars:
So I cut a mortice in the cill and tenon onto the frame:
I bought a mortice machine from the bay which I reckoned was a bit of a luxury purchase, but having tried cutting them by hand it took me ages and the results were somewhat rough so I'm pleased I did so. I've been sawing the tenons on the bandsaw, which has worked quite well.
Next I make some dowels out of oak:
...and cut the holes in the mortice and tenons, remembering to move the holes in the tenon 1.5mm out to allow the dowel to pull the joint tight:
I am greatly indebted to the video on Youtube from Chris Schwarz showing how to do the drawbore stuff.
Next I glue up and bash in the pegs and then clamp for good measure:
This particular window has an additional timber support on the top (complete with drip) which I have slotted onto the protruding tenons:
Now onto the window frame. I've forgotten to take a photo but I've cut out the mortice and tenons on the top and side rails. Now I need to add in the glazing bars, so more morticing and then shaping the rails to fit:
...and they do:
Dry fit to work out where the middle glazing bars will go:
I cut them out to fit as well (tricky business getting them to meet up in the middle!) and then make some more oak pegs and drill out the mortices:
... and tenons:
...before putting it all together with the glue, bashing in the pegs, checking it's square and clamping up:
Here is a pegged joint:
...and finally adding the wedges in to the top and bottom of the middle glazing bar:
Don't know if a lot of this is overkill, and I could certainly have done it a lot faster without so many traditional techniques. Also there are a few rough edges but it will all be getting painted so noone will ever know...
Now I need to consider how I will do the next five.
Thanks for looking,
Henry
