BACK to How to Assemble K-D Storm Sash



Trimming and Sanding the Sash
How to Trim Off Stile Horns, Tenons, and Finish the Joints

When all the sash pins are set below the surface,the clamps can be removed and put away.  If you wish, fill in the nail holes with wood filler.  After the wood filler is dry, plane the surface of the joint with a block plane until the faces of the stiles and rails are flush.  If no plane is available, Use a flat block of wood wrapped with 80-grit sandpaper to level the joints.  Sand the joints with a circular motion until the joints are level.

Cut off the tenons flush with the outside edge of the stiles with a handsaw or backsaw.  Plane or sand the tenons flush if necessary.

Next, using a small square, scribe the stiles even with the outside edges of the top and bottom rails with a sharp utility knife.  Scribe both the inside and outside faces of the sash as well as the edges. If you have an adjustable bevel square, set it to match the bevel of the bottom rail, and use it to establish the scribe line on the edge of the bottom end of the stile. Using a handsaw, cut the horns off of the stiles up to the scribed lines, cutting on the waste side of the line.  Use a block plane or sanding block if necessary to clean up the ends of the stiles, so that they are flush with the rails.

Sand the exterior and interior faces of the sash with an electric sander or sanding block using 100-grit sand paper, until smooth.

Using the block plane or sanding block, ease the edges of the sash slightly.  This step can be skipped until after the sash are fitted to the window frame, if desired.

Our standard K-D sash are made from Spanish cedar, which is a naturally decay-resistant wood that does not require any wood-preservative treatment.  After your sash are trimmed and sanded, they can be glazed or fitted to the window frame first and then glazed, whichever you prefer.

 

Click on images below to view at larger size.


Filling Nail Holes

Filling Nail Holes
Planing Joints Flush with Block Plane

Planing Joints Flush with Block Plane
Sanding Joints Flush with 80-Grit Sand Paper

Sanding Joints Flush with 80-Grit Sand Paper
Sawing Off Tenons

Sawing Off Tenons
Cleaning Up Joint with Block Plane (Or Sanding Block with 80-Grit Paper)

Cleaning Up Joint with Block Plane (Or Sanding Block with 80-Grit Paper)
Scribing Stile End Flush With Rail

Scribing Stile End Flush With Rail
Scribed Stile Face

Scribed Stile Face
Scribing Bottom Edge of Stile with Bevel Square to Match Bottom Rail Bevel

Scribing Bottom Edge of Stile with Bevel Square to Match Bottom Rail Bevel
Scribed Stile End Ready for Sawing Off

Scribed Stile End Ready for Sawing Off
Sawing Off Horns

Sawing Off Horns
Cleaning Up Stile End With Block Plane

Cleaning Up Stile End With Block Plane
Joint After Cleaning Off

Joint After Cleaning Off
Sanding Sash with Electric Sander with 100-Grit Paper

Sanding Sash with Electric Sander with 100-Grit Paper
Easing Edges with Sanding Block

Easing Edges with Sanding Block