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Preparing Sash for Assembly
Chamfering Tenon Ends Prior to Assembly and Making Grooved Clamp Blocks

The ends of the tenons should be chamfered slightly to facilitate sash assembly.  This is especially important if the joints are to be glued.

Make 2 (or 6 if you are using 3 bar clamps) wood blocks with slots for bar-clamp pads.  The slots allow the tenons to protrude through the stiles during the clamping operation. The blocks should be about 1-1/4" to 1-1/2" square by about 4" to 5" long with a 7/16" wide x 1/2" deep groove ploughed in the center of one side.

Click on images below to view at larger size.


Tenons Prior to Chamfering

Tenons Prior to Chamfering
Tenons After Chamfering, Ready for Assembly

Tenons After Chamfering, Ready for Assembly
Chamfering Tenons with Block Plane

Chamfering Tenons with Block Plane
Chamfering Tenons with Chisel

Chamfering Tenons with Chisel
Clamp Blocks-  1-1/4" to 1-1/2" Square  x  4" or 5" Long Blocks with 7/16" Wide x 1/2" Deep Grooves for Tenons

Clamp Blocks- 1-1/4" to 1-1/2" Square x 4" or 5" Long Blocks with 7/16" Wide x 1/2" Deep Grooves for Tenons