Made some barn windows

[Don P]

The barn we're working on needs some new windows. There was an old one that was worse for wear but it let me copy the style which was pretty simple, a tablesaw blade at a 20° angle is the molding pattern. That made making and coping the parts easy.
These are the stiles and rails;




This is a bottom rail and stile test fitted




Ripping the tenon haunches on the bandsaw




Using the hollow chisel mortiser on the drill press to finish the haunches. I also used it to punch the mortises in the stiles and rails. In the end I chucked up the 1/4" hollow chisel and punched diamond shaped peg holes in each corner of the frame through the mortises and tenons.




Test fitting the sash frame




Then fitting the muntins




And the finished product




These will be center pivot windows so that's easy, just a barrel bolt on each side into the frame and they will pivot and be easily removed.

I was really trialing these, now I need to jig up my clients farm shop and show him how, there are about 15 more windows to go. Anyway, simple windows for utility buildings are not that tough to make.

[Ea$y Money]

Your final product picture confirms that you have forgotten about more tools than I will ever own. (tips hat)

[SwampDonkey]

Those are dandies Don, good job. That's pretty much how they was made here on the old houses to. Packed the glass with putty. Of course them old houses was built like barns and just as cold. :D

[caveman]

Those look great.  Your easy projects would be my masterpieces.  

[WDH]

Very expertly done.

[samandothers]

I am with Caveman on this one!  Great job.  Reading and reviewing your pictures make it look and sound simple.  However the skill is in the execution and your final product really shows your skill.  Bravo!

[Don P]

I hadn't made any in 35 years. It didn't occur to me until the last year or two that my boss back then set me up. He knew of a beautiful old solid chestnut church up in the mountains where we could get married. When I talked to the pastor he mentioned that they needed the windows replaced and it was going to be too costly. I offered and my boss gave me run of the shop so Michelle was helping paint windows the morning of our wedding. This should have been a sign to her :D. Those had a molded thumbnail profile and I ground knives to match it but the coping was all with coping saw, knife and sanding blocks whittled to shape so my memory was of it being pretty time consuming. If you watch public tv in NC you've probably seen that old church. I've come to appreciate the simple craftsman style of these, everything was done with pretty basic shop tools.

[Ruffgear]

Nice work 👌, you make it look easy

[Bruno of NH]

Wonderful work Sir

[hacknchop]

You are one talented individual , it must be very satisfying to be able to make that barn retain it's appeal, in that most folks me included would replaced the windows with some modern vinyl clad window and it just would'nt be the same.

[scsmith42]

Looking good Don!