My current project is building windows for the new kitchen and master bedroom additions we'll be starting in the next few weeks. In the tradition of Loving Old Stuff, I couldn't bear the thought of putting vinyl windows in the additions. And in the tradition of I Love To Save Money, I couldn't bear the thought (or cost) of buying wooden true divided-lite windows either. Just one of those babies (for a good one) can cost several hundred dollars each.
Last August, I wrote about a couple of sets of window sashes that I rescued from going to the dump. (See my previous Historic Windows post.) I mentioned in that post that I had called my friend Bob Yapp to see if I could get him to pull together enough interested people to put on a hands-on training on how to build window jambs. Window jambs are the "frames" around sashes that hold the sashes in place. After several phone calls over the course of a few months, I pestered Bob enough to get him to do a private class for me. I headed up to Hannibal, MO to Bob's Belvedere School one weekend in February, and we built the prototype window jamb that will serve as the pattern for all the double-hung jambs I will be building.
Of the two types of windows I'm building (double-hung and casements), the double-hungs are the more complicated ones. Since I have my prototype to refer to for the double-hungs, I decided to start building the casements first. Casements are nothing more than a hinged door, so I reckoned I could figure those out on my own. The one change that I made to the casements is that instead of being an out-swing window as the were in the house where they used to be installed, I am converting them to in-swing windows so I can put storm windows on the outside to make them more energy efficient. They'll also weather better since they won't be directly exposed to the elements once the storm windows are installed.
|(click picture to enlarge)|
|Antique, yet brand new latch|
To make these windows energy efficient, I'm incorporating several features that will make these units on par with the efficiency of a vinyl insulated-glass window:
|Grooved stop molding, showing how a small|
section of the silicon bead is inserted. The
sash compresses the weatherstrip when the
window is closed, creating an air-tight seal.
|Groove in the bottom of the sash with the silicone|
sweep inserted. The white stuff in the foreground
corner of the sash is WoodEpox.