Key locations like mortises are transferred to the work piece by using a marking knife and a combination square. Next up is the use of a story stick - this traditional device is effectively a set of plans laid out on a piece of stock that matches the rest of your milled stock. Rails, stiles and muntin stock are run using the same setup on the machine - this way all the profiles are consistent. Profiled stock coming out of the molding machine We make a few passes to get near the finished size wanted and then a final cleanup pass at the end to leave the piece with a nice finish. (Shown above and below) Profiling the stock For larger runs a custom molding knife can make fast work of this often tedious task using a machine like the ‘Williams and Hussey’ molder. Sticking Knife Profile in the Williams and HusseyĪ profile can be run by hand using sash planes or using a router table. My wood of choice is Eastern White Pine, preferably quarter-sawn heart pine which is easy to work, weathers well and historically appropriate in my area - the greater Boston area. This post and the next are a high level recap of the course with some photos from building the prototype in my workshop and what we did in the classroom Nice quarter-sawn stock for muntins. Continuing Education Department at the North Bennet Street School, Boston, MAĪ few weekends ago I taught a two day workshop I developed on building a window sash at the North Bennet Street School. Early window sash were built by hand designed to be maintainable - if a component broke or rotted out it could be replaced - something that is not possible with most aluminum and vinyl windows you see on the market today. Building a window sash by hand can sound intimidating, but with some practice it can be an enjoyable experience.
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