Storm Window Frame

Today I decided to repair a storm window that fell apart because of dry rot. Yesterday I bought an eight foot length of a 2 X 6 from Home Depot. This morning I cut it to proper length. I knew that it would be 1/4" too thick so I used a router and a hand planer to get it to the proper thickness.

This was the first time I ever used a router so I experimented on a 2x4 to see if it was set at the proper depth and how it would work. The top photo is the piece of 2x4 I used to test the router. The lower photo is the the piece of wood to the proper thickness next to the rotted piece on the left. I feel the best way to use the router was to cut straight lines at the correct depth for the length of the board. I would cut 5 slots and then hand plane what was left. Any odd raised portions could be then chiseled off. The hand plane is best at shaving longer lengths of wood.

I had to cross cut the board. The original piece is cut at an angle on both edges. I got the first cut correct. Due to me only measuring once and not twice, I messed up on the angle of the second cross cut. So instead of the cross section looking something like /__/ it looks like /__\.

Next time, I'll have to remember to measure twice and cut only once. Meaning I'll have to watch to make sure I'm cutting it correctly.

Fortunately, I still had the second half of the 8 foot board and cut another 39-3/4" piece of wood and routed and planed the piece down to the proper 1-1/8" thickness. I work on the crosscutting on another day.

After I get the crosscutting angle correct then I'll have to work on the tenon joints on the ends. Then I'll have to get edging shaved for the window pane to sit on it. After that I'll have to get it into the bottom of the frame.