Cutting the joinery for the new sash sill

 


With the profile of the new sill complete, work could start on its joinery. Namely, the housings for the stiles, and the recess for the outer faces.


The first housing was measured in from the end and the edges sawn down to depth.


The housing was then chiselled out to a flat bottom


The sill was offered into position

With the remaining pulley stile seated in the first housing, the location for the second housing was marked from the remaining rear section of the sill.


Finally the recess for the outer faces were cut, and the housings were opened up to allow the stiles to be wedged in place from the outside.



Dowels were used to help align the sill during gluing, holes were first drilled into the new piece, and then dowel centre points were used to mark the location on the remaining old section of the sill.


Polyurethane glue was used again for both the dowels and the main glue surface between the two sections of sill. Wedges were placed underneath to prevent the outer edge dipping, and clamps held the two pieces tightly together.


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