The process of reproducing historic sash and windows begins with the assessment of details involving the period of origin to include joinery, materials and function. The window frames and sash are then carefully engineered and defined through our drawing process and 3D renderings.
Custom tooling is defined and procured to replicate original molding profiles for fabrication. Programming custom toolpaths for our CNC router also help to fabricate complex components. We construct our sash and window frames with premium grade hardwoods, western fir and cedar to meet project requirements.
Our window frames, sills and weight pockets are all interconnected with a web of dado, mortise and rabbeted joinery that locks every component together soundly. The sash styles, rails and muntins are assembled with traditional mortise & tenon joinery.
We use premium grade waterproof adhesives to glue all joinery. The finished assembly is then carefully hand detailed and sanded in preparation for finish.
Operative sash for double hung windows are counterbalanced with window weights positioned in enclosed side pockets that are integral to the window frame. We mortise the jambs precisely to receive sash pulleys and house the access panel for the weight boxes. The sash is then sized to fit in the frame and milled to integrate with sash cording and bronze interlock weatherstrip. Depending on the field conditions, the frames may be installed first with the sash to follow.
In preparation for glazing, the sash is first protected with an oil based primer. Glass, appropriate to period, is bedded and glazed with Sarco putty for a watertight seal. Once the Sarco glazing has cured, a second coat of oil based primer is spray applied on exterior and interior surfaces. Exterior topcoats (2-3) are spray applied with the customer’s choice of premium oil based or acrylic paint to the color and sheen specified. Our standard oil exterior finish utilizes Benjamin Moore Ultra Spec with a semi-gloss sheen. For acrylic finishes, we offer Fine Paints of Europe Eco satin (urethane-alkyd), Benjamin Moore Aura satin (alkyd) and California Ultra 2010 low luster (alkyd). Interior topcoats receive (2-3) spray coats of oil based Benjamin Moore satin Impervo to the color specified. The interior surfaces can be topcoated with an interior latex upon request. Our standard options are C2 Cabinet & Trim paint and Benjamin Moore Advance.
Historic windows and sash exist in a wide array of different shapes and sizes. We are experienced in meeting those variables, whether the sash is curved, elliptical, oval or otherwise. Our CNC machining offers precise joinery and layout for unique applications.
Once the window project is assembled, all units are inspected for proper functionality and counterbalancing of the window weight system. The final components to be installed are hardware (sash locks & pulls) and weatherstrip. Our standard weatherstrip system includes bronze interlock at the side and head jambs, spring bronze at the meeting rail and neoprene bulb at the bottom sash rail.
The last step to completion is delivery and installation. We will meticulously perform the installation or deliver it to your contractor to install. Our attention to detail throughout the process results in an
authentic replication of historic windows that truly enhances your home’s architectural style.
