The manufacture of windows, be it complete frames with sashes, sashes or just replacement frames has always posed a problem, probably because bought-in mouldings are never really the right size for the job and already profiled sections need the tenons to be hand cut. Accordingly, we offer sets of cutters for the production of either sashes or complete frames. Intended for one-offs these cutters will mould out the ovolo moulding and rebate all in one pass with additional cutters used for scribing tenons and moulding frames. For those just setting out for the very first time on this task the sections should be carefully thought out and a drawing done indicating clearances, rebates, etc. This will ensure that the job works out correctly. This will also be essential, as from the sections the overall length of the tenoned components can be calculated. Accordingly, whilst it may be thought that the moulding is going to be the first job, cutting the tenons will be the very first job. It is much easier to hold the section in the square and by clamping a piece of waste material to the sliding table of the spindle moulder (known as the spelch board), break out or splintering behind the cut will be minimised. With the tenons cut at one end, use of a cut length gauge can easily enable the second tenon to be cut. Here is where the calculations from the sectional drawing are important as the width of the sash or frame will be set with this cut. With tenons completed, the mortices can be set out and carefully machined. It is essential that for a good quality job, all face and edges are carefully marked and adhered to at all times. Once morticed the mouldings can be completed and for small glazing bars it may be necessary to make a holder (sometimes called a shoe) so that the small components can be safely machined without fear of accidents.
All of our cutters are standard 55mm with location pins at 24mm spacing, so will fit either the Whitehill Universal or Combihead blocks. The two cutters 64 and 65 have exactly the same moulding but allow for two different mortice sizes, either 1/2" or 3/8". Cutter 67 is intended for moulding and scribing the frame whilst cutter 66 is for scribing either mouldings made with cutters 64 or 65 or for moulding and scribing in their own right, i.e. in the manufacture of doors, arched headed windows, etc. Cutter 68 is a deep architrave cutter. In all, these cutters will make up an exceptionally useful set of standard mouldings. Remember, for hand fed proccesses you must use the matching limiters.
Cutters 64 and 65 are shown moulding profile and rebate all in one pass. Cutters 64 and 65 are scribed with cutter 66.
24 September 2018
Not quite perfect but still very usefulUndoubtably a useful set of cutters for traditional sash replacements or repairs, but with limitations. The ovolo section may be slightly too deep. Don't expect to produce a thin 21mm width glazing bar out of either cutters 64 or 65. Cutters 65 you might expect to be appropriate for 35/36mm stock given that they are set for a 3/8 mortice, but the ovolo size is, as stated, the same as for cutters 64 set for the 1/2 mortice width which is appropriate for 45/46mm stock. So, if using cutters 65 on 35mm thickness timber the mortice and tennon is annoyingly off the centre mark.