Re: DIY small wood window
I have a detached garage with 2 very crude single-sash
4-pane wood windows.
Both are badly worn. The bottom sash on one is rotten
and need to be replaced now. It is beyond repair.
How hard would it be to make 2 replacement windows from,
say, 5/4 treated deck wood? I gotta table saw, router,
drill press etc (no planer). Ran a fast Google search,
found no instructions, plans.
I can probably manage the mortise/tenon for the perimeter
wood elements. It's the "cross" in the middle that I
Any/all suggestions welcome ...
I wouldn't use PT lumber, I'd use regular #2 pine,
and paint it. As for the mullions, if this is a utility
window, just put regular rectangular strip across,
and half-lap a vertical one over it, and then use the
router to cut the lips to fit the glass in.
It would be easier to just user bigger glass, though.
I was thinking you could take the old mullions and essentially cut off
the back half. Looking from the front of the sash, you would cut it
where the dado (for the original panes) start. That would leave you
with the front shape of the mullions to stick on the outside of the
On Thu, 20 May 2004 13:44:25 GMT, Pudding firstname.lastname@example.org (Puddin' Man)
I've made afew windows in th past, but found that a local millwork
shop can do them quicker, better and for about the same price as I
spent in materials. If you do make your own, do as another suggested
and use a single pane. Window mullions aren't difficult to make, but
you'll get a better job with a single pane.
As for plans, you have them already. Disassemble the old sash.
Oh, if I had serious $, I'd probably get a shop to do 'em
for me, too.
I got some wood and plexiglas layin' around in the basement.
The shop can likely do 'em quicker and better, but not
I'll likely take your advice on this ...
The old sash is crumbling. And it was made in the shop.
Where they had different tools and different skills.
Hell, I couldn't even find any wood of really comparable
(1 and 1/8 ") thickness. Home Depot 5/4 treated is
hardly 1 " thick. The extra 1/8 " could make considerable
I coulda maybe used a DIY plan, but I can't find any,
so I'll wing it.
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