Texas window job

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Project by EzJack posted 09-30-2009 10:06 AM 1424 views 0 times favorited 8 comments Add to Favorites Watch

A customer brought me from Michigan to Round Rock Texas to install his windows for him. He has rock siding and couldn’t find anybody that could remove the old windows without disturbing the rock. He had one done and it was a nightmare so he fired the guy. The mortar is tucked right tight up to the nailing flange and any prying shakes the stone up… cracks the mortar. Not like brick where you mostly have a space. Anyway, I took a grinder and cut a slot. Then I ran a Sawzall blade between the flange and the stud to cut the nails. Once done with the cut around I cut a relief in the center of the channel and pried the old frame out smooth.
So the guy was happy and I suggested we make a drop in frame with a simple inlay for the inside. I had his daughter draw a horse head. I used oak, blood,and lace. The finish he said he would do and send me pictures. So here they are raw.
While we were waiting on the windows I remodeled a small bathroom.
The window replacement was the hardest I have ever done and that bath kicked me. I’m still trying to shake it off.

-- Ain't better or worse than any other woodpecker in the woods.

8 comments so far

View patron's profile


13603 posts in 3337 days

#1 posted 09-30-2009 11:53 AM

some of our jobs , can be a real bear !
and you always wonder if you were picked for your skill,
or if you were the only guy that was left ?

i like to make complete slide in frames too ,
keeps the site stuff down to a minimum ,
and you can make them square and finished in the shop ,

looks real nice , jack
i like your work !

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View John Stegall's profile

John Stegall

505 posts in 3512 days

#2 posted 09-30-2009 02:00 PM

If I had known you were so close, I would have had you do mine too (Kerrville). I am going to get to do my own, but I think I am going to retire first. In this economy, that may be a ways off. Nice job BTW.
EDIT: My mortar is already cracked, so that part won’t be my main concern.

-- jstegall

View Karson's profile


35120 posts in 4396 days

#3 posted 09-30-2009 02:12 PM

Great job on the windows. and the bath.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware soon moving to Virginia †

View Woodwrecker's profile


4148 posts in 3571 days

#4 posted 09-30-2009 02:50 PM

Good idea on the grinder slot & Sawzall Jack.

Those came out real nice.

And I bet that horse head brought some big smiles from his daughter.

-- Eric, central Florida / Utor praemia operibus duris

View Dick, & Barb Cain's profile

Dick, & Barb Cain

8693 posts in 4295 days

#5 posted 09-30-2009 03:36 PM

Very nice work, it must have been really labor intensive.

-- -** You are never to old to set another goal or to dream a new dream ****************** Dick, & Barb Cain, Hibbing, MN.

View childress's profile


841 posts in 3537 days

#6 posted 09-30-2009 04:43 PM

If you took the old frame out and installed a box window, what about the flashing?

-- Childress Woodworks

View EzJack's profile


456 posts in 3166 days

#7 posted 09-30-2009 07:55 PM

Very good question childress.
Before I took the windows out I cut a slot in the mortar between the stone and the windows for relief to chisel out the mortar after the window was out. Even with all the mortar out there was no room to properly flash. I grout bagged in the new mortar tight. sprayed a load of water on it and it did what I though, failed. We caulked them up with one fine bead and they held, not a drop. Of course this is fine for day one but not down the road without constant observation. From day one on this job I explained this to the home owner and he new what his responsibilities would be. He even did the caulking after I did the first one and showed him the best way.
Reasons why he went ahead.
(1) The existing windows were fogged up and designed in such a way the the fixed light was not removable.

(2) To remove the stone to flash them right was more than the customer wanted to do.

(3) There is a large overhang above every window.

(4) The customer wanted it and is willing to maintain it.

(5) Thus the reason for the drop in frames, they are for the windows of the most concern. They are made to come out very easy.

My personal opinion is that the way it was done and the way the house is set up it will never be an issue. The lesson here is not to go willy nilly into a job because the long term cost from unseen damage can be substantial.

-- Ain't better or worse than any other woodpecker in the woods.

View cabinetmaster's profile


10874 posts in 3554 days

#8 posted 10-01-2009 02:10 AM

Wow that was a way from home wasn’t it? Nice job. Can’t wait to see them all finished.

-- Jerry--A man can never have enough tools or clamps

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