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Windows

8/2/15       
Kevin Member

Hello, I am looking for advice on making wood windows for my 1850 Victorian. I am looking to make replacement units without having to use the existing pulley system. I have been looking at various jamb systems and am looking for feed back. I have a large cabinet shop but have never done windows before. Any thoughts?

8/3/15       #3: Windows ...
Farno

We just tried to do this and couldn't find a
balance that could be adapted to made-up wood windows nor could we find any neighbor who had successfully hung such windows other by using the weights, replacing the parting beads, etc. Available balances were incompatible with the weight and we feared problems in the long term.
PS: If you're in a historic district, regs on the color and type of balances may apply to you (as well as the type of glass; EX: UV reflective, true divided lights, double panes, etc.)

8/3/15       #4: Windows ...
Rob Scaffe

I have built a lot of double hung reproduction windows. Sash weights are simple, effective and an elegant solution-smooth as silk. Perhaps you need to replace the cord but you apparently have all the other parts. Stick with what you have, you won't regret it.

Best regards
Rob

8/3/15       #5: Windows ...
Kevin

Thanks for the responses. I have restored multiple old homes and gone through the pain staking process of restoring old windows. Our typical method includes steaming the sashes and carefully removing the glass. If a piece breaks we then install old salvage glass to maintain the look of the origanol window. We then sand, prime, glaze and so on.
When it come to the jambs we remove any old paint sand and then install new parting beads. I have always had the best luck using fir beads that we mass produce in the shop and then fit on site. My biggest problem has been getting a good fit in windows that have moved as the house as settled over the years. The other problem we encounter is were the sashes meet. I have milled new stock and applied them on site after the we have installed the sashes and that seams to work good. My biggest issue is time. To fully restore a window it takes one man about 8-15 hours depending on the unit size and condition. If I were to make these in the shop I figured we could produce two windows in a 8 hour shift in production mode easily per man. Again that with two shapers set up for my cope and stick, pre milled jamb stock, sills , glass stock pre ordered to size ect. My biggest problem is finding a counter weight system. I have thought of using the existing pockets and weights to match the new units. I think my next step is to take two days and make a test window and see how it goes. Thanks again for the ideas and feedback and look forward to hearing more. Kevin

8/4/15       #6: Windows ...
Rich

Website: http://www.hausmann.com

I have not ordered from this company but they should have what you are looking for.

www.blainewindow.com

8/4/15       #7: Windows ...
Joe Calhoon

Here is how we build DH. The pine section sample is not how we laminate. It was built from scraps.
Weights are expensive but you can make your own from bar or round stock. Save the old ones.
I prefer weighted but the one disadvantage to weight pockets is the heat loss. If you have enough room a foam insulation can be added to the outside lining. Usually not enough room in old 2X4 walls though.
Joe


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8/4/15       #8: Windows ...
Joe Calhoon

More pictures.
The frame is the labor intensive part of building double hung but a good system of S4S and moulded parts will cut down on time.


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View higher quality, full size image (960 X 1280)


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8/4/15       #9: Windows ...
gary

I agree with Joe that the traditional weight system is the way to go. I would completely remove the old windows and replace entirely with new units. Using solid 1-1/2" steel dowels with threaded holes at the top for eyelets makes an easy to adjust/shorten weight. A traditional double hung window properly weatherstripped with waxed jambs ( no paint) is simply the best working window ergonomically and in regards to adjustable air flow.

8/25/15       #10: Windows ...
E. F. Pionkowski Member

Website: http://islandfurnitureltd.net

We do a lot of sash windows and have used a supplier out of England for about 25 years - really high quality fittings and weights - www.reddiseals.com. have a look.


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