WORKSHOPS

Early 20th‑Century Window Replication

Location: Near McMaster University, Hamilton, Ontario

This project involved the full replication of an early 20th‑century double‑hung window system, built with respect for traditional methods and materials. Every step was documented with images—from rough lumber to finished installation—highlighting the authenticity of the process.

rough pine stock
Rough pine stock selected for tight grain—ensuring durability and stability.
Period hardware
Period hardware cleaned and restored: pulleys, cast iron weights, sash locks, brass lifts.
Vintage nails from Hamilton’s steel heritage.
Vintage nails from Hamilton’s steel heritage.

Materials & Preparation

  • Straight‑grain white pine selected from the mill, the same wood used in the original construction.
  • I specifically chose the tightest grain pine, adding durability and stability to the system.
  • Rough stock milled into precise components, including box frames designed for cold climates with grooved joinery to block wind.

Craftsmanship & Joinery

  • Pulley holes and weight access pockets cut into the frame.
  • Installation of parting slips—a detail often omitted, but essential. These keep the sash weights separated in the box so they don’t strike each other, reducing noise and ensuring smoother, quieter operation.
  • Traditional through‑tenon joinery, pegged and wedged, with joints painted before assembly for durability.
  • Hand‑applied bead on brick mould using a vintage wooden beading plane. (Image included.)

Trim & Detailing

  • Interior trim replicated: running trim, stool, apron, and back band.
  • Exterior trim including brick mould carefully matched to original profiles.
  • Putty detailing and painted finishes shown in process images.
Applying bead to brick mould with a vintage wooden beading plane.
parting slips for quieter sash operation
Installing parting slips to keep weights separated—quieter sash operation.
Pulley holes
Cutting pulley holes and weight access pockets into the frame.

Hardware & Industrial Heritage

  • Cast iron sash weights
  • Cast iron sash locks
  • Solid brass lifts
  • Original pulleys
  • Cotton sash cord secured with old nails from a vintage box.

Storm Windows

  • Traditional wood storm windows with stainless steel hangers and adjusters.
  • Designed to swing out awning‑style, allowing year‑round use and ventilation.

Performance & Conservation

  • Spring bronze weatherstripping applied for thermal performance.
  • Tested at Mohawk College: the conserved historic window system performed as well as a modern “top‑of‑the‑line” window in air infiltration tests.
  • Unlike modern disposable units, these windows are repairable and sustainable, preserving heritage while meeting contemporary standards.
Securing cotton sash
Securing cotton sash cord with vintage nails from Hamilton’s steel heritage.
Storm Windows with stainless steel hangers
Storm windows fitted with stainless steel hangers and adjusters for awning‑style swing
Final hanging of windows
Final painting and putty detailing for a period‑authentic finish.

Philosophy of Practice 

Authenticity over assumption: I never use conjecture; every detail is based on evidence and proven practice.

Durability through tradition: Tight‑grain pine, bronze weatherstripping, and hand‑tool methods ensure longevity.

Heritage as living craft: These windows are not disposable—they are repairable, sustainable, and part of a home’s ongoing story.

Industrial roots: My work connects Hamilton’s steel heritage with traditional joinery, bridging past and present.

Mentorship: As a teacher at Willowbank, I ensure these skills are passed on, keeping conservation alive for future generations.