The sash window design was invented by English scientist Robert Hooke. The oldest sash windows date back to the seventeenth century. This window style is classic and is normally found on Georgian and Victorian style homes. However, many contractors still apply this design on modern buildings and homes in the twenty first century. Precise instructions catered more toward personal preference can be located, but here is a quick look at modern manufacturing processes for wooden sash windows.
A window created in this design is made up of glass panes, otherwise known as sashes, that are movable. A typical window is comprised of two panes. In its original design, each sash is sectioned into three panels wide and two panels deep. This creates one large window with six panels on each pane. Traditionally, one of the sashes moves either vertically or horizontally. Some windows are designed with both having the same amount of mobility. When one or both of the sashes are moved, ventilation is created and is able to circulate air in and out of a room.
There are many tools necessary to build a wooden sash window. First off, you need wood and a table saw. A finishing blade and a dado blade will be needed to cut the wood to exact measurements. Wood glue, nails, a rabbeting bit, sandpaper and safety goggles are other supplies that will be necessary for this project as well.
Start by constructing a frame. With the table saw and dado blade, cut three eighth inch long extensions that are a quarter inch thick at the ends of the top and bottom pieces of wood. These extensions, or tenons, will be inserted into the side pieces of wood with slots cut out of the same size. This will keep the frame together. A chisel that is a quarter of an inch is used to square the slots on the side pieces. Use wood glue to adhere the four wooden pieces together. Wait for at least an hour to allow the glue to harden. Then use nails to secure and reinforce the pieces together. The nails should go into the tenons through the side pieces.
Now that the frame is sturdy, a rabbet, or notch, needs to be cut along the inside of the frame where the glass is going to be secured for the window. A rabbeting bit and quarter inch chisel will help ensure the rabbet is even throughout the frame. Before placing the glass into the rabbet, spread a glazing compound into the entire rabbet. A small string dipped in the glaze and then placed into the notch will help apply the substance. Lay the glass in the rabbet and push it down to make sure it sticks to the glaze. Add some more glaze to the edge of the glass to secure it in. Allow the glaze to dry overnight. Once the glaze has stiffened, the window is ready to be stained or painted.
Wooden windows are high maintenance. Because of the nature of wood, these windows are sensitive to wearing down due to weather. Hot and cold weather will constantly cause the wood to expand and shrink. Rainwater can cause mold and rot to grow in and around the wood. Also with sash windows, constant opening and closing of the panels will wear out the wood over time. The best way to restore a sash window is to build a new frame, following the same steps mentioned above.
The cost of purchasing or constructing such windows varies. If you build the window yourself, you pay for the materials and invest time, but you ultimately cut labor costs. If you search online or through the phone book, you can find companies or independent contractors that can make the windows personally for you, but their labor costs will vary depending on their rates.
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