Tuesday, October 13, 2009


Well, I built 8 pairs of sash, glazed and painted them 4 times in 4 weeks. Granted, I was working every day for about 15-16 hours. Ah...one of the many joys of owning your own business.
After the truck was loaded I set out on my epic adventure.
Day 1
Leaving Portland in the early morning for my first stop, Baker City. My hometown.

One word of note, the pictures in this post were taken out of a car window moving at between 65-80 mph. Not the best.

Day 2-Leaving Baker City on a lovely morning. No clouds and all sun which would come back and bite me later in the day as I crossed into Utah sweating buckets.

Entering Idaho.

Beyond this point there be dragons. Boise is the farthest east I had ever driven until this point.

Welcome to Utah. Hot!!
I spent the second night in Salt Lake City with some excellent friends. Good food, good company and Tour de France on Tivo.

This photo is for you, Grandma. Amazing building.

Day 3-After my poor 15 yr. old, 4 cylinder truck struggled to make it up and out of Parley's Canyon, we made it into Wyoming.

And then onto Nebraska. Which turned out to be my favorite state. I really liked the flat grassland and the wild weather.

So innocent looking off in the distance.
But later in the day it took on a more menacing look.

I was going to stop in North Platte which is in the panhandle of Nebraska but these dark clouds pushed me to go up the road to Grand Island. When I got into my hotel room and turned on the television there were all sorts of tornado warnings and watches for the panhandle area. I was glad that I had moved on.

Day 4- Early morning Nebraska farmland.

Finally, the destination. It is so small.

The first pair installed. What a moment.

The rest of them went in and then it was all over. I was finished onsite by early afternoon. Then what did I do? I went to downtown Atlantic, IA

Nice little factoid.

Short and to the point.

Day 5-Downtown Oakland. A town nearby on the way back to the freeway.

Abandoned church in Nebraska.

I drove on Day 5 from Atlantic, IA to Cheyenne, WY. It was a long day.
Day 6 was a short day into Salt Lake City. Just in time for Pioneer Day.
Day 7 was Salt Lake City to Baker City and finally on Day 8 I made it back to Portland.
I had a lot of fun traveling out to Iowa. It won't be soon forgotten.

Building Sash

The big pile of material waiting for the building of the sash to commence. The material is separated out for each pair of sash. I relied heavily upon Roy Underhill's book Working With Wedge and Edge for the proper sequence of cuts and other tips for making sash by hand. I recommend if you undertake this sort of project to get his book because the sequencing is very different from using power tools to do the work.

The sticking board. Crucial jig if you need to make thin muntin bars.

Using the sticking board with the new plane. Works like a dream. Thank goodness!

All mortices are chopped and the tenon checks are cut before any planes are used on the material. After these two operations are completed then I cut the glazing rabbet first and then the molded edge.

Another tip from Roy's book was the use of guide sticks. They are scrap pieces of wood that I marked out where the mortices and tenons started and stopped. I ended up having to make two sets of guide sticks because I had two different sizes of openings.