Window Sash

Our Expert

Sash & doors undergo additional stress because they are exposed to two different environments simultaneously. The exterior is exposed to the extremes of the weather while the interior is in a stable, controlled environment. Because of this it is best to choose a stable wood that holds up well outdoors. Douglas fir and western cedar are both good choices for sash or doors that will be painted. Mahogany is a good choice when a natural finish is preferred.

Regarding the tenons, modern glue does not require as much surface area for a strong joint as the hide glue which was used centuries ago. That being said, stub tenons are surprisingly strong and work well for certain applications such as kitchen cabinet doors. However, large architectural sash and doors undergo much more stress because of the additional weight of the door and/or glass panes. When constructing architectural sash & doors I prefer the additional strength of mortise-and-tenon joinery.

There are two methods for creating mortise-and-tenon joinery with cope-and-stick router bits. One way is to route mortises with a plunge router and a straight bit such as Amana Tool no.45426 and use a loose tenon to reinforce the joint.

Another method is to use Amana's new door making bits which will soon be available.