How to build a 100+ year old window
Furnished content.
(from WoodNet.net)


I have been asked by a friend to build some new windows for his 100+ year old house. He has about 5 that have rotted from the bottom up. I told him to bring me one and I will give it a test run. I was hoping maybe I could just trim the bottoms off and add on a new solid piece, but that is not going to work. They are going to need to be completely rebuilt. The stiles ran all the way from top to bottom which allowed them towick water up. And that rot has gone higher than the top of the bottom rail. Iam looking for some advice on wood type, adhesive type, joint type,and any other pitfalls I should be aware of.

They are pretty basic 4-piece wooden frames with a rabbet to hold the glass and then glazing compound over the glass to hold it in the rabbet. There are no divided lights.They are just single pane glass. It looks like on the two top corners that are still intact that it is assembled with what I think is called a bridle joint, but instead of a singe tongue fitting between two tongues, each piece has two offset tongues. Kind of like a box joint with only two tabs on each piece. I can take some pictures and add them here if it would be helpful.

I don't think I have to match any of the original construction techniques - just make them look the same as the original when I am done. So what wood, adhesive, and joinery would you use?

I have total boat high performance epoxy that I have used for inlay fills, but have never used it as an actual adhesive. I suspect something like that would be better than any of the normal wood glues.

I built John TenEyck's horizontal router mortiser and was thinking this would be a good application for that.

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