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Clutchcargo 12-17-2011 12:53 PM

Building Barn Sashes
 
I want to close off my front entryway portico. This is unconditioned space so I thought barn sashes would be adequate. I went to my local lumberyard to price barn sashes. I figured since it's one pain of glass it would be relatively inexpensive; wrong. It's actually relatively expensive. The total for all the glass panels would come in around $1400 for a portico that's 3'x 8'.

Anyway, I don't have money but I'm fairly confident in my skills and have all the tools needed to build these sashes, so I think I'm taking that route. I'm thinking cape code style, so all square cuts.

So the first questions of many likely to follow is:
What species of wood should I use for sashes that will be painted on all sides?
Anyone know of a good online resource for instructions?

TIA

BigJim 12-17-2011 01:47 PM

Cypress, Spanish Cedar, Redwood, Western Cedar, Mahogany and others. Do you have any pictures or drawings of the sashes?

oh'mike 12-17-2011 01:58 PM

Quote:

Originally Posted by jiju1943 (Post 796017)
Cypress, Spanish Cedar, Redwood, Western Cedar, Mahogany and others. Do you have any pictures or drawings of the sashes?

Also--do you have a table saw and a router table?

Clutchcargo 12-17-2011 02:06 PM

Thanks,
I don't have any pics of what I want to build but simple divided light. The largest RO is on the sides (about 27x80). The front will contain a storm door, surrounded by sidelights and transom. The sizes are still flexible at this point as the openings are not framed yet.
I have all the tools I'd need: router, router table, SCMS, and table saw.

oh'mike 12-17-2011 02:19 PM

I'll let Ole Jim help you----I'm not up to speed on exterior sashes----

Clutchcargo 12-17-2011 06:26 PM

I found an old finehomebuilding pdf that shows a decent anatomy of a sash. Since I want to keep it simple (without any molded edges) it should be fairly straight forward. A drill press, which I also have, will make the mortises easier.
Alright, next week I'm off to the lumberyard to see what I can get for a decent price from the above wood species. Thanks again for the list.

BigJim 12-17-2011 06:40 PM

CC, there are several ways to build the sashes, the easiest is to buy the router bit sets made for windows.

http://www.amazon.com/55-801-Shank-W...5707642&sr=1-3

http://www.amazon.com/s/qid=12457076...w%20sash%20bit

By looking at the configurations of these bits it is easy to see how it is done. You can also make the parts with a router table using several different bits without buying the window cutter sets.

You can also make square sashes using a table saw or a slotting cutter, set up in your router table and a table saw.

The window sets are used somewhat like making cabinet door rails and stiles. I have actually made windows using a cabinet door set but there is a little more work to it.

Are you planning 6 over 9 or 9 over 9 or what?

BigJim 12-17-2011 06:43 PM

Quote:

Originally Posted by Clutchcargo (Post 796254)
I found an old finehomebuilding pdf that shows a decent anatomy of a sash. Since I want to keep it simple (without any molded edges) it should be fairly straight forward. A drill press, which I also have, will make the mortises easier.
Alright, next week I'm off to the lumberyard to see what I can get for a decent price from the above wood species. Thanks again for the list.

You must have posted as I was typing. Do you have a link to the site you found?

Clutchcargo 12-17-2011 06:52 PM

I'm unsure what the light configuration is going to be. Now I'm thinking the big panels will be non-moving. That would simplify things greatly. I wasn't thinking of the window frame and the window weights (or some kind of counterweight) that would need to go into it.
Here's the link for the pdf. It's dated December 1983 but I can't imagine that there have been many advances in a simple barn sash since then.

BigJim 12-17-2011 10:44 PM

CC, that looks pretty straight forward, following that format and you will get it done. If we can help let us know.


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