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How to make a window

making a shed window




Instructions - Making the window sash   Page 18 of 21  

The window sash in this project is made out of 50x50 (2x2) dressed/surfaced lumber, however the actual size of the lumber when dressed finishes at approximately 45x45 (1 1/2"x 1 1/2"). Since this may vary slightly from place to place, make any necessary allowances.

Full page contents are at the bottom of the page.

The window sash is the moving segment of the window. It is the framework that holds the panes of a window. The sash is fixed to the window frame with hinges. Refer to the drawing identifying the window parts in the previous page

You will need four pieces of 50x50 (2x2) dressed/surfaced lumber: 2 pieces approximately 430mm (17 3/4") long and 2 pieces approximately 330mm (13 3/4") long.
You will also need a piece of 3mm (1/8") thick acrylic sheet (plastic glass) for the pane, a couple of strips of wood for the decorative grille, some glue and 4 25mm (1") angle brackets.

Step 1.
Cut a grove 12mm (1/2") deep and 3mm (1/8") wide up the middle of a piece of 50x50 x 1600 long (2x2 x 64" long) lumber.
This can be done by making a cut with a circular saw or a bench saw. If the groove is not wide enough to accommodate the acrylic sheet (plastic glass), then a second cut will be needed to widen the grove.

Next cut the 4 sash members to length: 2 pieces at approximately 490mm (19 5/8") and 2 pieces at approximately 390mm (15 5/8"). Angle each cut at 45°.

  parts of the window sash

NOTE: The length of the above sash members are only approximate. If the window frame is already made (see previous page), then that will determine the required overall size of the sash.
Ensure there is a gap of at least 5mm (3/16") between the sash and frame all the way around.

Step 2.
Cut the acrylic sheet to size. The size will be 20mm (3/4") bigger than the inside measurement of the sash frame.
Next glue and screw the sash members together ensuring the acrylic sheet is fitted into all the grooves.

Cut and glue strips of 10mm x 10mm (3/8"x 3/8") wood to the acrylic sheet (plastic glass) making a cross.
This is solely decorative and the size of the wood can vary depending on personal preference.
Use an exterior type glue that will adhere to both wood and plastic.

  window sash

NOTE: For added strength fix 25mm (1") angle brackets to the external corners of the sash frame. When doing so, make sure the window will still be able to open freely without the angle bracket rubbing against the window frame. The angle bracket may need to be checked partially into the sash.
NOTE: For extra weather proofing add some free flowing sealant or mastic to the grooves before fitting the acrylic sheet.

NOTE: This complete plan-set can also be purchased in downloadable PDF format free of advertising and print friendly for only $5. To purchase click here

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CONTENTS
bullet Page 1:  Introduction and Contents
bullet Page 2:  Identifying the Members - Terminology
bullet Page 3:  Helpful Information
bullet Page 4:  Shopping List and Cutting List
bullet Page 5:  Plans - Footprint and Front Elevation
bullet Page 6:  Plans - Rear Elevation and Side Elevation
bullet Page 7:  Plans - The Roof, Cuts and Angles
bullet Page 8:  Floor - Option 1, Lumber
bullet Page 9:  Floor - Option 2, Concrete
bullet Page 10: Instructions - Wall Frames
bullet Page 11: Instructions - Roof Frame
CONTENTS
bullet Page 12: Instructions - Roof Cover
bullet Page 13: Instructions - Wall Cover
bullet Page 14: Making the Door
bullet Page 15: Making the Door Frame
bullet Page 16: Installing the Door
bullet Page 17: Making the Window Frame
bullet Page 18: Making the Window Sash
bullet Page 19: Installing the Window
bullet Page 20: Instructions - Gable and Soffit
bullet Page 21: Instructions - Inside Finishing




   
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