Rotted bottom rail in window sash.

[guthrie]

Hello.  Restoring windows as part of painting an exterior and have to replace bottom rails of six lights sash.  My problem or question is that the rot goes into the vertical rails mortise and tenon and the owner wants to save every bit of original wood.  Is that foolish to do or should we just mill them all new?  That is my question.

[johnleeke]

It's not at all foolish if they want to preserve their historic wood and will pay you to do it. After all, its their wood and their project.

It is possible to do wood-epoxy repairs that are as effective and durable as part replacement.

I often let the owner make the decision to repair or replace window parts. I will cost it out both ways, wood-epoxy repair of the stiles, and wood part replacement of the stiles. It is sometimes an economic decision and the owner will select the lowest cost. It is sometimes a philosophical decision and they will want repair rather than replacement without regard to cost. Depending on the conditions and situation wood-epoxy repairs might cost more or less than part replacement. If it's an important historic site and funding is available, they may even be willing to pay more to save every fiber of remaining wood. 

For more on wood window repairs you may want to consider my Save Your Wood Windows training session coming up in May:

http://www.historichomeworks.com/hhw/education/seminars.htm#HHWWindows

where I'll be demonstrating the use of ConServ epoxies in window repairs.

John Leeke
by hammer and hand great works do stand
www.HistoricHomeWorks.com

[Paul Marlowe]

Guthrie,
I don't think saving as much original fabric as possible is foolish.  My approach would be as follows:  The verticle stiles should have the bottom ends prepared by removing the soft wood decay then apply liquid borate preservative, allow the wood to dry to 18% moisture or below, consolidate endgrain w low viscosity epoxy #100 & fill voids w flexible epoxy patch #200 to recreate all the original profiles.  The new rail should have the visible endgrain treated w the same specification of preservative & epoxy to seal & inhibit future decay fungi.  The patch can then be tooled & parts reassembeled.  If you replace the stiles also treat the ends as described for the rail.
Paul

[evergreen]

I have been specified to use salvaged "first growth lumber" for replacement of rotten window rails.  Is this really a good idea and where do I get it?  I'm not sure I want to run salvaged lumber through my shaper because you can't tell what's in it.  How do you know its clean of metal?  Any comments are welcome.

[Paul Marlowe]

Evergreen,

First growth lumber will be more rot resistant & stable.  You should be able to purchase it from antique building salvage companies.  You can use a metal detector & close visual examination to find buried metal. 

Paul