Thread: Timber window frame construction advice.

I thought about this kind of thing my self because i was thinking of changing my crappy alminium single pane doors to double glazed timber ones. I asked a few people and got the impression that no-one really attempts it commonly because (a) Second hand timber windows and doors are in ready supply in most cities and you can usually find something to suit or adapt, (b) windows, doors and frames are somehat tricky to build as they are often big, have lots of angled mouldings and rebates and getting them assembled, square and installed is a challenge in a home workshop. Also, as no houses are ever perfectly square most replacement doors or windows are ordered 10mm smaller above and sides than the hole and filler or packing pieces and cover strips are used to allow for variation in dimensions of the cavity. Thus they don't generally build the window out of square to fit the house as it makes things too complicated, particulalry if moving components are involved

I don't want to put you off trying to DIY but I don't think making windows from scratch is particularly easy. You could look at Burraboy's 'French Doors WIP' for a how-to guide on the process. His thread doesn't include the frame construction just the doors but you'll get an idea of the techniques. Have you looked in the Renovators Forums?

Hi Roy

your local library should be able to get a copy of
Modern Practical Carpentry by George Ellis -- the 3rd Edition from 1927 has recently been reprinted
earlier versions are available

George covers all you need to know to build windows and doors

Here's one I prepared earlier, about 12 years ago actually, just after we bought this house and I needed to replace a window or two. (Please disregard the garbage bin out the back.)



I actually managed to get a couple of double glazed panels close to the size I wanted on the cheap and built the windows around them (I did two in this room). I made them as awning windows, the hinges and closers are easy to get. I was mindful of needing to get a good seal to prevent heat loss and built in a rubber seal between the frame and the awning. The timber was treated pine for all the exterior bits, but Cedar would be a good choice. There is no fancy stuff on these. M&T's and square finishes. It was a quick and effective solution and does not look out of place. Talk to some glass suppliers and see what you can pick up to make the job cheaper. If you keep it simple it is not a big job!

Originally Posted by burraboy

I actually managed to get a couple of double glazed panels close to the size I wanted on the cheap and built the windows around them (I did two in this room).

I was actually hoping to do it the other way around by getting a set of cheap second hand frames and then ordering the panels to suit. Trouble is no second hand frames have come up that have been the right size and I got put off by the size of the job... this is sliding doors not windows I am talking about mind you. So, Burraboy, did you make all the framing or just the window component cos there seems to be a lot more to it if you include the architraves/cavity frames as these tend to have mouldings and rebates galore?

THis is what I love about forums, a little searching and the right questions yield a world of advice!! Fantastic!!

Thanks to all, this is exactly the sort of information I have been looking for. Feedback and examples. I'll be off to the library tomorrow to have a look for the book to see if I can get enough info for the one project or see if it's worthy of aqusition.

burraboy, your frames are exactly the sort of thing I have in mind, possbly with a little more detail but its little steps first.

Cheers,

Roy.

A door build like that would be interesting, I'd like a good look at the slide mechanism first because I'm not familiar with that, but i think I would have a go at it. Second hand would be the first choice, but if that doesn't work out then designing a way to do the job as simply as possible would be my approach. Rebates are pretty simple and there are a lot of pre-cut architrave mouldings out there. How easy can you make it?

Hi plane sailing. I'm currently helping my uncle make 50 windows for his house (yeah it's a big house) out of Rosewood.

Our design is pretty simple. We haven't used any fancy mouldings. They are sash windows so we've routed out for spiral balancers on the sliding windows. If you're doing hinges obviously you don't need to worry about this.

For the rebates we used the bench saw to make the two cuts you can see in the second pic. The crosses are easy cos you can go all the way through...but the styles had to be stopped short. The waste was cleaned out with the router and squared with chisel after glueing. Did this to save the router from certain death and us from the mess. If you're only doing a couple then probably rout everything when glued up I guess.

Joins are mortise and tenon. I used a bench mounted router for the mortises, 12mm bit, then reversed it to clean up to about 14mm and make it dead centre. Tenons cut out with the radial arm saw. Set stop for depth of tenon. Set depth for thickness of tenon. Cut shoulder neatly first then clean up the waste. Chisel corners of tenon to suit mortise.