The wife has been wanting me to buy some old windows for hanging pictures in and placing them on the living room wall. Most of the windows we could find were priced way to high. The ones I was able to get my hands on have been to far gone to even use as a picture frame. I have reticently acquired two old Stick and rabbet planes. So I set on the journey to teach myself sash. I have a few old windows to look at the construction. Even around the 1900’s they were using machines to cut the molding. There construction is almost like modern day cabinet doors. When they were done by hand the corners were coped in to give the look of a mitered joint but retain some water shedding ability. To do the coping method you have to have an in-canneled gouge. I do not have one so I choose just to do a miter. Each corner taught me a lesson and I then move to the next. I found that free handing was no where near accurate and thus built a miter jig for pairing. Proper layout is a key. And cutting the tenons before planing is a must. here is a short video and pictures tell a lot more. I did use an old window pain and its imperfections are nice. I could not toss out the test piece so I finished it and gave it to the wife. She liked it and it awaits a picture. Please ask questions.
-- Superdav "No matter where you go - there you are." http://chiselandforge.com