A couple of weeks back I was asked to build 4 Queen Anne sash for an 1895 house in West Linn, Oregon. At the time I was very excited to build these as my own house is a Queen Anne Victorian and I would like to replace some of my vinyl's with something more appropriate. But it soon turned into quite a challenge.
The homeowner provided me with one original sash to use as the sample and an old photo taken of the house in 1915. The material originally used was Western Red Cedar, my new least favorite species to work with. In Oregon most 19th c. sash are either Douglas Fir or Western Red Cedar. This cedar is very prone to tearing and it dents very easily. My chisels and irons had to be kept very sharp. I spent a lot of time at the whetstone and strop.
The beginning of the first pair-layout. (Note my beloved anvil in the background.
You wouldn't believe how hard it is to find a good anvil.)
Mortises cut, now onto the fun stuff-cutting the rabbet and molded edge.
Using the moving fillister to cut the glazing rabbet (rebate for those of you in Europe).
First pair built, primed, and glazed with colored glass.
Onto the next pair which were much more challenging. Twice as many lights.
Lots of scribing and fitting involved with the grid.
44 hand-cut mortise and tenon joints per 21 light sash.
Finally assembled, many hours later.
I will post some photos of the glazed sash once they are completed.