Repairing sash with rotted tenon on lower rail


Remove pins holding rail to stile

Trim any remaining good wood from tenon.

Cut blank to fit in mortise.  Glue rail to stile and glue blank in mortise.

With flush trim saw, remove excess blank.  When dry, drill holes through blank into rail.  Glue dowels and trim flush.

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9 thoughts on “Repairing sash with rotted tenon on lower rail

    1. Hi John,

      The blank doesn’t extend into the rail – it only serves as a gluing surface for the dowels, which do extend into the rail. (Rather than forming a mortise in the rail for a floating tenon – which seemed like a lot of work – I just plugged the mortise on the stile and used dowels as joinery.)

      Thanks for reading.

  1. OK, I get it now. I though you “slotted” the rail and the new blank also fit into the rail, re-creating the old tenon.

    Are you getting enough widow work there?

    John

  2. Nice to see a fellow craftsman wanting to repair instead of replace, Its rare these days.I also have a window repair company in the Twin Cities that does these sort of repairs,looks like you do great work. Jay Window Reworks

  3. Gary, Michael and Jay:

    I’d like to invite you to get involved in a project a bunch of us “putty heads” have cooked up. It’s call the National Window Standards Collaborative. You can check it out here:

    WPSC Website:
    http://ptnresource.org/WPSC/

    Participate in writing the Standards and learn more here at the WPSC Forum:
    http://ptnresource.org/WPSC_forum/
    (click on the “People…” section there, and then “Founders” to learn more about those involved.)

    There are a couple of ways you could participate. If you have more time you could be a “Stakeholder,” reviewing and commenting on the drafts at the website Forum. Get started here:
    http://www.ptnresource.org/WPSC_forum/viewtopic.php?f=11&t=12

    take care, work safe and keep in touch,

    John Leeke

  4. Just spent some time reading all your posts, and this one in particular is one of my exact problems. I’ve had plastic over the window for some time now while trying to find a new sash, or decide whether or not I want to pursue a new window. (I live in a historic district in Missouri, so they all have to be approved.) Anxious to give this a try! Thanks for posting!

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