The making of the usual Victorian windows, with hollow frames and sashes to slide up and down with cords and weights, was then a job cherished by the joiner. Every workman aspired to possess his complete set of sash ovolo moulding planes; his sash fillister for taking out the rebates to receive the glass; his brass-ended mitres for fitting the ends of the sash bars; his double-tooth gauge and mortice chisels.
Walter Rose, The Village Carpenter, 1937
Oh, to have my complete set of sash ovolo moulding planes! I spent all week restoring old sashes: two are original to the Cardinal Mill; I made an entire new one and in this photo I am trying to figure out how to re-size another old window to fit the openings at the mill.
This window is getting a new bottom rail, the old one was rotted and being on a tight schedule, I don't have the time to stabilize the wood with liquid epoxy. It's quicker to make a new rail.
This sash was missing all but 2 of its muntins, Mike and I spent about an hour milling some yellow pine into new muntin material. The only hitch was that I couldn't find a router bit that matches the original ovolo, and again, we don't have the time to have one specially made for the shop.
A brand new lower sash to mate with the original upper sash that I pulled out
of the mill. I made it as an exact copy of another original window as I could.
Here I am sawing out the mortise on an original stile for a new bridle joint.
Michael Lohr is a Park Technician II with Boulder County Parks and Open Space. He is also a wonderful photographer, do check out his website! In this photo, he is making his first muntins, he was very excited about learning how to make sashes. Mike is also a wonderful glazier, a hundred more windows and he'll be the best glazier ever! Hurray! That means I won't have to glaze windows anymore!
Last week, Mike had problems cutting glass, this week he got the hang of it, no more broken pieces, crooked cuts or over-sized cuts.
Yes, I do glaze windows and I am really good at it! We use DAP Brand Painter's Putty 53, it's readily available, it costs $9.95 at McGuckins Hardware in Boulder and it is a linseed oil and calcium carbonate glazing. Most other linseed oil based glazing is available only through mail order.
Stay tuned for more posting on work at the Cardinal Mill!