Let There Be Light — Installing New Hand Built Windows

In many posts we’ve talked about why old windows are worth saving and how to build or restore  sash for them, but not much on what it would take to build a new window complete with jamb and trim and install it.

Completed window installed in the side of the barn
Completed window installed in the side of the barn

A while back I had just such an opportunity when working on the timber framed barn workshop of my friend Rich. Much of the work for these windows took place in the shop — building traditional single hung (one moving sash) true divided light windows. A hand built window can offer a VERY long service life, be easily repaired and often look much better than anything you can buy commercially. The ability to build a new jamb to go along with your sashes will allow you to really fine tune the movement of the windows, the exact choice of hardware — if any and allow you to create a distinctive look for your home.


Bill cutting through the wall to install my window.
Bill cutting through the wall to install my window.

Once the shop work was completed, the jamb is complete, the sash are fitted, glazed and the paint has dried it was time to install the completed window unit into the barn.  When working on a timber framed barn you’ll want to make sure you’ve carefully laid out where you want the windows to go — you generally do not want your window obstructed by braces or other framing members. You’ll also want to make sure that you have added in sufficient nailers and/or studs so that your window can be firmly attached to the building.

These hand built windows, complete with jamb, sills, casing and leaded flashing install much the same way you would install an Anderson or Pella new construction drop in window. You’ll want to take the same time and effort to level the window, add insulation if needed, and flash out the window. Once installed you can trim out the interior of the window to blend with the interior surfaces.

Me posing with the newly installed window
Me posing with the newly installed window

If you’ve invested the time to learn how to build a traditional window sash, building an entire window as described here can be a very enjoyable and rewarding experience — plus with these new found skills you can go off and build a window of any size and shape.

Below is a quick slideshow of the above windows being installed into a timber framed barn.

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