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Hi everyone... I am considering purchase of the Bosch 1617EVS Router and RA1181 Benchtop Router Table for a window sash project. I want to be sure I will have enough power and that the table fence will be accurate enough. I am also considering the Kreg bench table. My sash are relatively small residential profiles. Im looking to duplicate MW window sash to replace a few that are rotten. Thanks in advance!
 

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John
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Hello and welcome to the router forum
 

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Welcome to the forum. Have you looked to see how to replicate these sashes? The type and size of the bit as well as the fence depth might make a difference.
 

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Ross
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Welcome to the forum.
 

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i do a lot of storm window replacement, generally use a stackable shaper cutter set and a shaper. if you buy a sash set it will probably
be 1/2 shank and need a decent size router and a heavy stable table set up to do job.
 

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There is a lot to making window sashes including the type of wood and the quality of the wood. By the time you've invested several hundred in the tools and lumber, you may find that things just aren't working out. I can see it with a historical building but for an average house, you'll be better off, in the long run, to just get new replacement windows. However, if you decide to do it then build a table yourself so that you have one that will give you enough support to make accurate profiles. I'm the last person in the world to advise not to DIY but there are times where you have to pick your battles.
 

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There is a lot to making window sashes including the type of wood and the quality of the wood. By the time you've invested several hundred in the tools and lumber, you may find that things just aren't working out. I can see it with a historical building but for an average house, you'll be better off, in the long run, to just get new replacement windows. However, if you decide to do it then build a table yourself so that you have one that will give you enough support to make accurate profiles. I'm the last person in the world to advise not to DIY but there are times where you have to pick your battles.
I made my own windows 20+ years ago for my shop. 9 double hung windows in the shop and two sashes that swing inside in the loft. I used 6/4 Luan for the rails and stiles. The sash are 6 pane top and bottom. Glass is double pane glass set in putty. .I am a more than a DIY , I am a retired carpenter but this was the first try at making windows. I got information by studying the Anderson drawings .
Frames and sills are PT decking boards that are primed and painted.
Windows turned out great. I believe the total cost at that time was under $75.00 for lumber , hardware and glass.
I would not recommend doing this for a DIY.
 

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I made my own windows 20+ years ago for my shop. 9 double hung windows in the shop and two sashes that swing inside in the loft. I used 6/4 Luan for the rails and stiles. The sash are 6 pane top and bottom. Glass is double pane glass set in putty. .I am a more than a DIY , I am a retired carpenter but this was the first try at making windows. I got information by studying the Anderson drawings .
Frames and sills are PT decking boards that are primed and painted.
Windows turned out great. I believe the total cost at that time was under $75.00 for lumber , hardware and glass.
I would not recommend doing this for a DIY.
I made my own windows 20+ years ago for my shop. 9 double hung windows in the shop and two sashes that swing inside in the loft. I used 6/4 Luan for the rails and stiles. The sash are 6 pane top and bottom. Glass is double pane glass set in putty. .I am a more than a DIY , I am a retired carpenter but this was the first try at making windows. I got information by studying the Anderson drawings .
Frames and sills are PT decking boards that are primed and painted.
Windows turned out great. I believe the total cost at that time was under $75.00 for lumber , hardware and glass.
I would not recommend doing this for a DIY.
I have made a few windows in my day but it was before replacement windows were so common. With the cost of lumber today I can't imagine what they would cost in materials not to mention time. It would be easier to replace the whole window with a cheaper wooden one than try and build a sash to fit and it would most likely be a better built draft free window. One other option would be to contact a window replacement company and offer to buy sashes that they remove that would fit the opening. But there is a reason that people replace old wooden windows.
 

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I have made a few windows in my day but it was before replacement windows were so common. With the cost of lumber today I can't imagine what they would cost in materials not to mention time. It would be easier to replace the whole window with a cheaper wooden one than try and build a sash to fit and it would most likely be a better built draft free window. One other option would be to contact a window replacement company and offer to buy sashes that they remove that would fit the opening. But there is a reason that people replace old wooden windows.
Hi everyone... I am considering purchase of the Bosch 1617EVS Router and RA1181 Benchtop Router Table for a window sash project. I want to be sure I will have enough power and that the table fence will be accurate enough. I am also considering the Kreg bench table. My sash are relatively small residential profiles. Im looking to duplicate MW window sash to replace a few that are rotten. Thanks in advance!
I made several sashes for our daughter’s lake cabin that was built in the early 1900’s. I have the same router and table you are considering. I bought sash router bit set 55-802 from Infinity tools. They have a very good instruction video on making sashes. They were quoted $500 per window from a local carpenter. I made them for way less than half that using 5/4 clear white pine. Nine windows/ 18 sashes. Of course I made them for cost of materials only.😊
 

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