Replacement windows

We are taking out the old windows and and replacing them with new split pane frames. Hopefully, this will cut down on thermal transfer and driving noise. A single piece of safety glass big enough to fill the entire opening was going to cost north of $100 per window, so we are going to reuse the glass from the old frames. This means we will have split pane windows, but I couldn't justify the expense for new glass.

We have finished forming all of the pieces, and are working on painting them before assembly. This entire process has taken me over a month and three trials before I finally got something that I liked.

I started with 2 by 3 pine stud material and planed it down to the correct dimensions on the first try. But it was hard to find knot free, straight lumber.

For the second try, I bought poplar from a local hardwood supplier. This required less planing but was going to be expensive to make 19 windows.

On my last and, fortunately, final experiment, I used pressure-treated balustrade sticks from Lowe's. I still had to cut them to length and plane them to the correct dimensions, but they were much straighter than the longer stock and I could pick relatively knot free pieces.