I keep getting emails about this so wanted to clear up some confusion. The drawing in the video was provided by the original person who reached out to me about help figuring out how to make these frames. He informed me the drawing is NOT accurate up to a 1/4 inch in some cases. I would happily provide people with the drawing for free, but with it not being accurate it will not be of much help. If someone really wanted a scaled drawing I wouldn't mind making a master copy for people, but I would need an intact cross section of the window in order to do that.
When I rebuilt my sash, I watched your video multiple times and I followed your example pretty closely. I printed off some screen shots of the drawing for reference. I too thought that having the original drawing would be helpful, but in retrospect it really wasn't necessary; the left half of the bottom of my sash was intact so I could take the measurements from that. You did not appear to rely on the drawing, but instead measured everything carefully and transferred the measurements to an orthographic drawing so I did the same. I was tempted to skip starting with a pine test piece before I cut the final piece out of oak, but I'm glad that I didn't; I made some mistakes on the test piece that I corrected before cutting the final piece. I am a real amateur and a slow worker so I spent several days between removing the sash and putting it back in. If I were to give a bit of advice to someone with similar skills who wanted to tackle the same project, it would be to temporarily replace the sash with a piece of plywood and then take your time with the rebuild. You were a very good teacher.
@@JollyViking Jolly, is there any way you could post or email your drawings? My bottom sash is completely disintegrated. The top is intact, but it appears I would do significant damage to the top and sides trying to disassemble them to measure. I am hoping to make just the bottom piece. Thanks in advance!
@@JollyViking Yes - if you happen to have transcribed your profile into a drawing, would love a copy. I'm very versed in CAD, could make a drawing and post it back. I may have to do that anyway - just to have something to work from.
I’ve been an architect for almost 40 years. I had Pella casements in both my houses. My current house is 27 years old and the Pella lower sash on my casements are rotting. Pella has been in several class action lawsuits regarding rotten window components. I will not spec them any longer. The other issue is Pella changed the sash profile Back about 2002, so replacement sash units are not available now rendering my windows obsolete. I’m glad you made this video, as at some point I will have to make new sash components to repair my rotten window parts. I’m going to use Spanish cedar. Thank you for posting.
I did a little reading about the windows and it from the comments of people that had them. If you managed to even get money back it was a fraction of what was spent on the windows. Some people had windows rotting in less then 10 years. My parents live in an old Victorian built in 1887, before pressure treated lumber. All the windows are still original. To spend that much money on new windows for them to fall apart that quickly is absurd.
You call them 'how to' videos but there's definitely something of the masterclass about everything you do and the depth of detail you're prepared to give in your extensive commentary. Watched this twice as it is relevant to so many similar window and other opening framing jobs I need to do and it's helped a great deal. I feel that sometimes having your hands near the blade can be less dangerous than giving the piece too much room for play but it does call for added concentration. Great video - thank you for posting it. Your friend is lucky to have you.
Thank you! Thank you! Thank you! We opened one of our Pella windows last spring only to have the rotted bottom fall out. We feared that we would have to replace all three double casement windows on that side of the house, but by following your excellent instructions, I was able to repair the badly rotted window sash. Luckily the other windows were in decent condition so we will be able to refinish and reseal them without rebuilding. You saved us a fortune. Thanks again.
The Shinto rasp is quite the multi-tasker. For the price it hard to beat. Shaping handles for a shovels or rakes, faux live edges, cured spray foam, ect… You should be very proud Caitlin of this. So much to unpack in your method, but you nailed it. Thanks for sharing.
Thank you! I'm having the same dilemma right now. We built our house ourselves and put these exact windows in it. It's really disappointing to discover the rot. Your video is excellent!
So much kudos to you for taking the time to help so many people to hopefully fix a major problem with their window units, especially as you are a working shop and are not getting paid for this, I am sure the person who originally asked for your help is very grateful for your instructional video for him to make his own or otherwise find someone who could help him closer to home 👌👌👌👍👍👍🇦🇺
Wonderful job Caitlin. Definitely a lot of various cuts needed. Thank you for sharing. Everyone stay safe, warm, happy and healthy. From Henrico County Virginia
Your skill level is extremely high, you are a very safe maker. I thought the way you used your jigs was very calculated and safe. This is a very complicated and tedious recreation. I am a very experienced maker myself, I always enjoy watching your videos because I always learn from your how to's, great job!!! Timothy
Thanks. I always like to point out the safety with certain cuts. Just with the nature of the camera and depth perception sometimes they look more dangerous or my fingers look closer to the blade then in real life.
Making these in a small home shop is do able for sure! The disadvantage is the cuts made at the factory are a one and done! Making them on a tenoning machine in one pass is far easyier for sure! Nice job!
Thanks for the tips on positioning the work piece and your hands for the table saw. Every tip or reminder helps me focus on safety. And great camera work also. Thank you.
Good stuff! I always appreciate the thought and work that goes into window fenestrations and their construction details. Sash work is a great way for anyone to push their skills. Great video 👊 thanks for sharing ✌️
I’m always impressed by your technical skills and creative problem solving, however this one was absolutely amazing!! You should be very proud HB, heck, I’m proud of you 🤙🏻🤙🏻
Thank you Caitlin. This is another very topical subject for me personally. Our home has 50 year old Pella windows and a sliding door that are giving some problems. What species of lumber did your customer request? Always love the way you show the all the steps and your jigs for making repeatable and accurate cuts.
Doulas fir isn’t a badly rated exterior wood, it’s just not the best. If it was my only option I would use it and prime it well. KDAT : pressure treated kiln dried wood is what I would try and find. Because using well rated exterior lumbers like white oak or mahogany would be a sin to use on something like this.
Thank you so much for this tutorial. I have Pella pro line that I need to make . The bottoms are all rotted out. Excellent tutorial do you have the drawing available that you are working from. I will follow your tutorial and try my self. Thank you
I do have the drawing, but it won’t help. The guy that gave it to me said it’s not accurate up to an 1/4 inch in some spots. The best way to get measurements is if you have a piece that is structural enough to make a cross section and pull dimensions from there.
@@HoneyBadgerWoodWorks I understand where you going. I have completely rotted window bases so your tutorial will help me get a good start. Thankyou again
Hello. I'm dealing with one of the larger windows in my parrents house as well as a sliding glass door. Both of them are rotted out to an extent on the bottoms. Where did you get the CAD drawings? I am skilled enough at wood working that I could rebuild them for several hundred dollars vs the $12-15k Pella is going to want. The door alone is well over $8k today. Great video and thank you for posting this as I've been trying to figure out how I might rebuild what they have rather than replace. This gives me hope if I can get my hands on the drawings somehow that I can save some $.
The CAD drawings came from the guy I made the video for. If I remember correctly his friend made them. I would gladly give them too you, but he informed me that they are actually not accurate. Some of the dimensions are off by more then a 1/4 inch. If you have enough good lumber left you can cut a cross section and use that to make a drawing.
Nice job. I hope I never have to make something like that, but if I did, just watching your video makes me think maybe I could. But I probably wouldn’t. 😉 But you do give me courage to try the hard stuff.
I have a TON of Pella windows in my house - which is almost 30 years old. Only a couple have rotted sashes, and after seeing this (and knowing that Pella will want to replace the whole window with a new product) - I will make my own. I have both a good table saw and table router, so I can make just about any profile. I have one cracked glass pane - does anybody know where/who can supply the glass component to these windows?
Awesome video. Only problem is the wood rotted so much there is nothing to trace in my case. my glass cracked as well. Pella couldnt provide me measurement of the glass. I have to find a place I can have one made up. i want to order the glass without taken it off first.
KDAT. The closet seller is over an hour from me. And then I would have to ship the parts to him as well. My schedule is tight these days so I was hoping this how to video would help him out. Or find someone locally is more cost effective.
![DIY Double Insulated Glass || Save Money [How To]](http://i.ytimg.com/vi/DXcnbdHcrps/mqdefault.jpg)
I keep getting emails about this so wanted to clear up some confusion. The drawing in the video was provided by the original person who reached out to me about help figuring out how to make these frames. He informed me the drawing is NOT accurate up to a 1/4 inch in some cases. I would happily provide people with the drawing for free, but with it not being accurate it will not be of much help. If someone really wanted a scaled drawing I wouldn't mind making a master copy for people, but I would need an intact cross section of the window in order to do that.
When I rebuilt my sash, I watched your video multiple times and I followed your example pretty closely. I printed off some screen shots of the drawing for reference. I too thought that having the original drawing would be helpful, but in retrospect it really wasn't necessary; the left half of the bottom of my sash was intact so I could take the measurements from that. You did not appear to rely on the drawing, but instead measured everything carefully and transferred the measurements to an orthographic drawing so I did the same.
I was tempted to skip starting with a pine test piece before I cut the final piece out of oak, but I'm glad that I didn't; I made some mistakes on the test piece that I corrected before cutting the final piece.
I am a real amateur and a slow worker so I spent several days between removing the sash and putting it back in. If I were to give a bit of advice to someone with similar skills who wanted to tackle the same project, it would be to temporarily replace the sash with a piece of plywood and then take your time with the rebuild.
You were a very good teacher.
@@JollyViking Jolly, is there any way you could post or email your drawings? My bottom sash is completely disintegrated. The top is intact, but it appears I would do significant damage to the top and sides trying to disassemble them to measure. I am hoping to make just the bottom piece. Thanks in advance!
@@JollyViking Yes - if you happen to have transcribed your profile into a drawing, would love a copy. I'm very versed in CAD, could make a drawing and post it back. I may have to do that anyway - just to have something to work from.
I’ve been an architect for almost 40 years. I had Pella casements in both my houses. My current house is 27 years old and the Pella lower sash on my casements are rotting. Pella has been in several class action lawsuits regarding rotten window components. I will not spec them any longer. The other issue is Pella changed the sash profile Back about 2002, so replacement sash units are not available now rendering my windows obsolete. I’m glad you made this video, as at some point I will have to make new sash components to repair my rotten window parts. I’m going to use Spanish cedar. Thank you for posting.
I did a little reading about the windows and it from the comments of people that had them. If you managed to even get money back it was a fraction of what was spent on the windows. Some people had windows rotting in less then 10 years. My parents live in an old Victorian built in 1887, before pressure treated lumber. All the windows are still original. To spend that much money on new windows for them to fall apart that quickly is absurd.
Wow! So much detail on these cuts!
You call them 'how to' videos but there's definitely something of the masterclass about everything you do and the depth of detail you're prepared to give in your extensive commentary. Watched this twice as it is relevant to so many similar window and other opening framing jobs I need to do and it's helped a great deal. I feel that sometimes having your hands near the blade can be less dangerous than giving the piece too much room for play but it does call for added concentration. Great video - thank you for posting it. Your friend is lucky to have you.
Thanks. Happy you got something out of it!
Thank you! Thank you! Thank you!
We opened one of our Pella windows last spring only to have the rotted bottom fall out. We feared that we would have to replace all three double casement windows on that side of the house, but by following your excellent instructions, I was able to repair the badly rotted window sash. Luckily the other windows were in decent condition so we will be able to refinish and reseal them without rebuilding. You saved us a fortune.
Thanks again.
No problem. Really happy this video helped someone.
The Shinto rasp is quite the multi-tasker. For the price it hard to beat. Shaping handles for a shovels or rakes, faux live edges, cured spray foam, ect…
You should be very proud Caitlin of this. So much to unpack in your method, but you nailed it.
Thanks for sharing.
Thanks. I have use it quite a bit since I got it. Great tool and not too expensive.
Thank you! I'm having the same dilemma right now. We built our house ourselves and put these exact windows in it. It's really disappointing to discover the rot. Your video is excellent!
No problem, I hope it helps. Hate how they weren’t held responsible for a faulty product.
So much kudos to you for taking the time to help so many people to hopefully fix a major problem with their window units, especially as you are a working shop and are not getting paid for this, I am sure the person who originally asked for your help is very grateful for your instructional video for him to make his own or otherwise find someone who could help him closer to home 👌👌👌👍👍👍🇦🇺
I haven’t heard from him about the video yet, but in general he’s been very appreciative of my help trying to get this problem sorted out.
Wonderful job Caitlin. Definitely a lot of various cuts needed. Thank you for sharing. Everyone stay safe, warm, happy and healthy. From Henrico County Virginia
Thanks!
Your skill level is extremely high, you are a very safe maker. I thought the way you used your jigs was very calculated and safe. This is a very complicated and tedious recreation. I am a very experienced maker myself, I always enjoy watching your videos because I always learn from your how to's, great job!!! Timothy
Thanks. I always like to point out the safety with certain cuts. Just with the nature of the camera and depth perception sometimes they look more dangerous or my fingers look closer to the blade then in real life.
Making these in a small home shop is do able for sure! The disadvantage is the cuts made at the factory are a one and done! Making them on a tenoning machine in one pass is far easyier for sure! Nice job!
I know. It’s crazy what money and big machines can do.
Thanks for the tips on positioning the work piece and your hands for the table saw. Every tip or reminder helps me focus on safety. And great camera work also. Thank you.
Thank you HB, great how to, you are a master in your class no frills just talent.
Thanks!
Excellent demonstration, you did a great job of explaining the process. I guess you will have to become a Pella subcontractor.
Naw, windows aren’t my thing. Especially poorly built leaky ones.
Good stuff! I always appreciate the thought and work that goes into window fenestrations and their construction details. Sash work is a great way for anyone to push their skills. Great video 👊 thanks for sharing ✌️
Windows and Glass Pane doors are in my opinion some of the harder things to make and take awhile to master.
Awesome job. Really enjoyed your methodical approach to the task. Subscribed 👍🍻
I’m always impressed by your technical skills and creative problem solving, however this one was absolutely amazing!! You should be very proud HB, heck, I’m proud of you 🤙🏻🤙🏻
Thanks. I’m always surprised by what projects people are impressed with on here. Getting a lot of positive comments on this one.
Thank you Caitlin. This is another very topical subject for me personally. Our home has 50 year old Pella windows and a sliding door that are giving some problems. What species of lumber did your customer request? Always love the way you show the all the steps and your jigs for making repeatable and accurate cuts.
He wants to have them made out of KDAT.
You mentioned that the Douglas Fir wood not be your choice of woods. What species would you recommend for Minnesota?
Doulas fir isn’t a badly rated exterior wood, it’s just not the best. If it was my only option I would use it and prime it well. KDAT : pressure treated kiln dried wood is what I would try and find. Because using well rated exterior lumbers like white oak or mahogany would be a sin to use on something like this.
Very very Nice work as always!!!👌💯👍
Thank you so much for this tutorial. I have Pella pro line that I need to make . The bottoms are all rotted out. Excellent tutorial do you have the drawing available that you are working from. I will follow your tutorial and try my self. Thank you
I do have the drawing, but it won’t help. The guy that gave it to me said it’s not accurate up to an 1/4 inch in some spots. The best way to get measurements is if you have a piece that is structural enough to make a cross section and pull dimensions from there.
@@HoneyBadgerWoodWorks I understand where you going. I have completely rotted window bases so your tutorial will help me get a good start. Thankyou again
Hello. I'm dealing with one of the larger windows in my parrents house as well as a sliding glass door. Both of them are rotted out to an extent on the bottoms. Where did you get the CAD drawings? I am skilled enough at wood working that I could rebuild them for several hundred dollars vs the $12-15k Pella is going to want. The door alone is well over $8k today. Great video and thank you for posting this as I've been trying to figure out how I might rebuild what they have rather than replace. This gives me hope if I can get my hands on the drawings somehow that I can save some $.
The CAD drawings came from the guy I made the video for. If I remember correctly his friend made them. I would gladly give them too you, but he informed me that they are actually not accurate. Some of the dimensions are off by more then a 1/4 inch. If you have enough good lumber left you can cut a cross section and use that to make a drawing.
Nice job. I hope I never have to make something like that, but if I did, just watching your video makes me think maybe I could. But I probably wouldn’t. 😉
But you do give me courage to try the hard stuff.
Nice, I was hoping to break it down into digestible parts.
@@HoneyBadgerWoodWorks
Well you definitely did a good job of that. Thank you.
I have a TON of Pella windows in my house - which is almost 30 years old. Only a couple have rotted sashes, and after seeing this (and knowing that Pella will want to replace the whole window with a new product) - I will make my own. I have both a good table saw and table router, so I can make just about any profile. I have one cracked glass pane - does anybody know where/who can supply the glass component to these windows?
Awesome video. Only problem is the wood rotted so much there is nothing to trace in my case. my glass cracked as well. Pella couldnt provide me measurement of the glass. I have to find a place I can have one made up. i want to order the glass without taken it off first.
That sucks. You would think at the least they would have a cross section with measurements for the original wood.
@@HoneyBadgerWoodWorks With the lawsuit they probably dont want to provide any information.
That’s a good point.
Nice job!!
Great video
Why type of wood was your client looking to use?
KDAT. The closet seller is over an hour from me. And then I would have to ship the parts to him as well. My schedule is tight these days so I was hoping this how to video would help him out. Or find someone locally is more cost effective.
It’s a shame that you did all of that for a demonstration piece…..Hall of Fame woodworking!