6 Comments

This sounds like an extremely interesting build. Is that a Festool Domino joint? Half-inch-thick glass that large must weigh a ton! Are you going to post a photograph when it is in its new home? We’d love to see the final project.

L/W

This is a domino joint; though, it could be made with most m&t jigs. Virtually all of my joinery is m&t-based.
The purpose for the post is to demonstrate one approach to updating, perhaps improving upon, a previously accepted practice- the window frame itself was instructive for me, but would be rather tedious for someone who has done more than one.
Also, I was uncomfortable supporting the weight of the glass with a traditional exposed m&t,
Once the client views the dry-build, I’ll sand progressively from 220 to 600, then finish with a Zinnzer sealcoat and sprayed Deft Acrylic – the specific intent is to enhance the Sapele grain and down play the sheen.

What an awesome project. Last year I had the opportunity to cob job repair some antique windows (in place – mostly just bondo). We got a quote from a reliable window contractor to remove and repair the sashes for $10k per window. Crazy price. The owner balked and I ended up doing it myself, but like I said – it was a cob job and not a real repair.

Also, since you mentioned sapele, I have a little experience with it. I had to repair a sapele veneer cabinet in place a few years ago, so I called the millworker that made it to see how he finished it. First, he shellaced it, then used a satin poly. I followed his instructions and it came out perfect – totally matched the existing finish. To this day, I don’t know why he used shellac first, but shellac does slightly “amber” the color even when its not amber shellac. It looks nice. Gives sapele a rich color – the lighter highlights become golden more than blond. Looks great.

I’ve done a few restoration sashes and adding the Domeno is a great precaution against joint failure. Good Job.

https://www.artisticwoodstudio.com/videos

Brian:
Sapele is an excellent project wood. Here, in Annapolis, it is readily available in 8" – 13" widths, 6/4: it is my preferred wood for rocking chairs – the ribbon grain can be quiet attractive when designed-in.
My next commission is a contemporary desk and side-table – in Walnut and Hard Maple – this should be interesting… Sapele might be too dramatic for a full-width desktop (~60″ × 27″).

You can see your skill in your work , excellent