While Eric is busy in Bay 2 starting the frame, I have been making the window sashes. There are 30 sashes needed for the side windows, 4 in the ends that are narrower, and 30 clerestory window sashes. In addition, I assessed the state of the windows in coach 3. None of the main window sashes are original, and most need repair. Not only that, they are either the wrong type of wood, or don't have the correct design features. The end windows do appear to be original -- they are made of quartersawn white oak, and have the original anti-rattle springs on the sides, as well as a number stamp on one edge. One of the end windows is in poor shape, in the end where there was a fire at one point. So we decided that as long as I was to go into production on one set of windows, I would also add 30 new window sashes for coach 3 sides, one end window, and 15 clerestory windows. That led to a grand total of 110 new window sashes.
Here is the pile of 200 or so board feet of rough quartersawn white oak that I started with (mid November):
After a few weeks of planing and machining, the pile was reduced to the component parts cut to final length and width:
The first task was to do all the mortises, a total of about 450, each requiring multiple passes:
Then cut the tenons, which require 6 different setups in total. Here is one of the clerestory rail tenons next to the corresponding mortise:
Here's what it looks like assembled. I like the stopped chamfer on the inside edges, it adds a nice touch.
A stack of the finished clerestory sashes waiting for final sanding and bottom bevel:
The pieces of the main windows ready for assembly. The odd features on the rail sides are for the anti-rattle leaf springs. I attached a picture of one of the originals below.
This is a stack of about half of the main window sashes, fully glued and sanded:
Moving on next to the main doors....
