Having recently completed the "Fabulous Fake Door" project for the 250 year old stone portion of our home, it was determined that the four windows on the first floor were beyond salvage, even with extensive re-glazing, etc. There is a bit too much rot and punk and they leak like sieves, anyway. My first thought was to get custom sized, so-called, replacement windows but quote came in a nearly a grand apiece due to the odd size and color requirements. (and that's contractor price which I qualify for and from multiple manufacturers) The existing windows haven't opened in probably 50 or more years. They are single hung with zero counterbalance, even if they could be restored. If they opened, a prop would be needed to keep them that way. So given there's no way we're going to put $4000 into four windows and the consequences of having a non-opening solution are pretty much status quo anyway, I decided to make new, fixed pane replacements with double-insulated, low-e glass panels and wooden framework that pretty much looks identical to current...minus the rot, of course.
Having determined the required dimensions (28.375" wide by 46" tall) for the shopping exercise mentioned above, I designed a framework that would slip into the available opening once the old windows are stripped out and use the existing interior beaded window surround to contain it on that side. The means an unchanged appearance in the wide, "pie cooling" window openings in the 18" thick stone walls. As you'll see, the simulated divided lights, etc, are a layered built-up grid that interlocks with the basic frame. Even with the dry-fit that's done on all four as I type this, they are very solid and once the final, beaded appearance layer goes on the outside after assembly with the glass, it will take a bomb to pull them apart...or at least a whole lot of time passing into the future at which point it's not likely going to be my concern.
My regular local lumber source is back to being open, so I paid them a visit to acquire material. 8/4 clear pine wasn't available, so I chose 8/4 poplar for this project. That's thicker than I need, but I will use the extra thickness for all the thin stock I need to build up the grids. No waste, in other words. I bought (2) 11' sticks of 9" wide material. Morgan, the young lady who tends to the lumber shop most of the time, cut them to two slightly over 8' sections plus the leftover so I could fit them in my Ascent...I didn't bring the trailer for just two boards. Back at the shop, I halved the longer pieces as those sections were adequate for the longest component. When milling lumber, I prefer to keep things short for processing.
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After flattening, I managed to thickness to 1 7/8" which left enough for a 1.5" thick window frame plus 1/4" thick stock for the grid as noted above.
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Straight-lining...
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Ripped to generous width
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Re-sawing to get the thin strips
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Nothing like using both the workbench and the slider outrigger for convenience when resawing!
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