If needed, get your hinge side stile to fit against the frame. I aim for a 2mm gap all the way the casement, so if it's tight for width, remove 2mm before you start
Next, with the stile pushed tight to the hinge side, also allow a 2mm gap on the top and bottom. If somethings slightly out of square you may need to remove a few shavings to get the joints parallel. Don't be too hasty doing this. It's easy to remove too much VERY quickly !!
Next step is to think about where you're going to put the hinges.
Fairly near the top and bottom is best. On longer sashes you can use 3, but I think 2 should be adequate for this.
I chose to keep them 30mm in from the rebate line.
Set a marking gauge to depth, allowing for a 2mm ish gap. This might mean going slightly deeper or shallower then the leaf thickness.
If you wind back to machining the frame, you'll remember using a hinge to get the position of the rebates drip groove. This will be the height of your hinge, so set marking gauge to this.
Next step- hedgehog time !
With the your hinges chopped in the sash/casement, offer it into the frame. Ensure you've got your correct gap top and bottom (note 2mm packer in top gap), then transfer hinge lines to the frame.
Square the lines into the rebate and chop in the hinge recess to the frame
I find it easiest to chop the frame vertical. Before having a tail vice I always chopped the frame hinges with the frame flat on the bench. Whatever works for you [WINKING FACE]
A small mallet and butt chisel is definitely a blessing when mallet swinging is restricted.
Take off the closing leading edge. I prefer to do enough so the closing side shutss, but is still tight enough to plane the 2mm gap once the sash is hung.
Im sure this'll be obvious, but to ensure you don't remove anything from the front edge (only leading edge) keep your plane away from it.
Pilot drill one hole in each leaf. Use a normal pozi instead of the slotted brass, to make life easier.
Check the hinge side gap is correct.
Remove shavings on the closing side so you've got a 2mm gap when it closes.
You should also have a 2mmish gap between the inside of the sash and frame rebate
When you're happy with the gaps remove sash, and machine a drip groove around the entire outside of the sash.
This should be in line with your hinge recess.
There was a tiny slither left (poor machine setup) so I chiseled it off.
Sand up edges.
That's all there is to it !!
Temporary pozi screws for making hanging/removal easier.
A few shavings from-
Will help it to sweep past the draughtstrip easier.
That's it folks.
Hope this may inspire someone to have a go at making a window. Having a massive amount of tools can help speed things up, but the reality is, everything could be done with fairly basic tools if time isn't an issue. I'd say one of the most important things is to check your dimensions before getting out the glue pot.
I've got a few more pics of painting,fitting, but feel this is probably a good place to stop.