warmtone

Hi Tim, thanks for an excellent article which has helped me visualise how these seemingly simple windows are constructed. But in woodwork nothing is quite as simple as it first appears!!

I am currently trying to repair an existing sash window (dry rot in lower rail) and trying to make a replacement lower rail..... The construction of my window is different to what you show here as the window uses a coping joint between the rails, stiles and muntins- making repair a real challenge.

To succeed I need the router bit set with exactly the same profile as my 40 year old window.

While the the profile is a simple (half round approx 9mm) finding a suitable set is not easy - as most window bits I have seen here in Australia are a more decorative Ogee pattern. Do you have any suggestions for suppliers??

As a second thought, I could make a whole new window using your design above as I only need to find ONE profile bit and avoid the coping joints entirely Do you use a jig to hand cut the miters or some other method?