Wooden window rebating

[JKWoodcraft]

Hi Everyone,

First time asking - hope you can help...

I have a customer who wants to change his single glazed, Georgian style 6 pane windows to double glazed.

I'll be fitting slimline dg units so I need to cut the rebate deeper (min 9mm - or more as I might be beading them in instead of butyl putty). There's 25mm of timber to go into so I'm ok there. I can lay the removable windows flat and router them out ok (i think) but does anyone suggest an option or technique for the fixed windows other than trying to run a heavy router around vertically ??

Should I just use a light, rotary tool to cut them? Or is there another way ?

Cheers to all for any info or suggestions.

Jim

 

[gregmcateer]

Jim,

Although I haven't started on a similar project - when I posted up a similar question, I received the following;
(Sorry I thought I could post a link to it, but I can't) -

Search in General Woodworking for the topic - 'Convert single to double glazing'

Hope that's helpful

Greg

 

[nickds1]

Jim - I've just used these:
http://www.wealdentool.com/acatalog/Online_Catalogue_Flat_Sash_Ovolo_set_650.html

...from Wealden Tool Company to make some replacement casements for old 12mm double glazing units that had "popped" and replaced them with 18mm units by using these plus a deeper rebate and thinner beading. The result, when viewed, looks just like the original symmetrical ovolo - its a neat solution - the ovolo is the same width, just a lot shallower thus giving more space for the glazing...

Nice helpful company to do business with...

 

[Ollie78]

For the fixed windows you could try a little trim router (bosch GFK 600, or the nice little Makita one) and a straight bit.
Be careful its easy to smash straight through glazing bars !!
A good way is to use a baton or pair of batons set to the correct offset to the router, fix the baton to the face of the window and run the router up all the verticals then all the horizontals. Its a bit labour intensive but you can`t really use a router fence for this as you won`t be able to get anywhere near the corners. You can`t easily use a bearing guided rebate but either as there is not much to run the bearing on.

Pay attention to the direction of the router for safety. you will still have to chisel the corners a bit and scrape or sand the edge a tiny bit but I have done this a few times with good results.

Also I would not use beads, it never looks nice and they will rot out fast. Butyl putty is ok but the best thing is Dryseal ( Brewers and Dulux decorator centres sell it) not cheap but extremely good especially for double glazed units.

Ollie

 

[JKWoodcraft]

Just a quick thanks for the replies. Will post more when I get back to looking at this job....

 

[plug]

Done this last year on some old oak windows, I used the small trend router with a small bearing guided striaght cutting bit. I fixed a piece of 150mm timber to the window so it was flush with the glazing bar the ran the router along it.
Very slow job think it took over 2 weeks for all the windows.

 

[CHJ]

Many moons ago there were Stepped Glazing units available (outer pane larger than the inner) to fit in single glazed frames without having to change the rebates, are these still available.