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New Sash Fabrication in Mahogany

The original stained glass window on the south elevation of the sanctuary was somehow lost. Circa 1970 a replacement was put in by others that did not match the original and was failing structurally after 35 years. Information about the original window amounted to a framed picture. All remaining stained glass windows in the sanctuary were smaller and a dissimilar configuration but helpful for glass and pattern match. Designing a new wood sash to hold up for a long period time hinged on availability of quality material. Mahogany may at first seem an extravagant choice. After considering the many other resources being invested and this materials ability to withstand weathering Genuine Mahogany was an excellent choice.

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South elevation (date unknown) as it appears in the framed picture provided by the congregation.

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South elevation as it appears today with the replicated window installed.

In the foreground is one of the beautiful pieces of Mahogany used to fabricate this sash.

Determining an initial relationship between the pattern and the mahogany blanks under it was crucial to a good design.

After individual pieces were cut from the blanks a mortise was machined into each end of each joint.

Above a tenon is fit too each joint and later cut to match the exact profile. Traditional joinery is not easily achieved.

Individual pieces of the sash are pulled together then held in place with sash pins.

Profiles and detailing are being added (above) after assembly.

A completed sash and a proud craftsman.

Click here to view the repair of wooden sash page.

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31323 Colon Rd. Colon , MI 49040
Phone: (269) 432-2610
Fax: (269) 432-9411

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