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.
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°.
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.
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.
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
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