Customizing old leaded windows to replace existing frame

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Forum topic by Nelly posted 07-22-2012 12:10 AM 1263 views 0 times favorited 4 replies Add to Favorites Watch
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4 posts in 2401 days

07-22-2012 12:10 AM

Topic tags/keywords: windows leaded retro-fit question refurbishing

I’m looking for assistance on a project. I have two old leaded windows that are just shy, size-wise, of fitting into an existing frame. I have basic knowledge of wood-working, am willing to take the time to do this correctly. The existing windows open out from the frame. These windows were built very “inexpensively” and did not hold up well.

My idea is to do the following:

1. Fill in channels on leaded windows (grooves for the ropes) with the spray-on expanding foam. After hardening, trim excess foam.

2. Cut lengths of fir to build out lead window. (1/2” for width, 1” for length), clue and nail onto leaded window perimeters.

4. Install flashing on top of window if necessary.

3. Install with existing hinges on window frame.

Any suggestions? Warnings?

Thanks for any and all help.

Nelly Crowe

4 replies so far

View oluf's profile


260 posts in 3061 days

#1 posted 07-22-2012 03:29 AM

I doubt that those windows are made strong enough to be used as hinged units. The rope groves tell me that they were double hung sashes. they were supported on two sides in channels, The strength of the sash (ledded glass0 kept them from racking corner to corner and breaking the corner joints. You could use some “L’ corner brackets, but I still think you will not be happy in the long run.

-- Nils, So. Central MI. Wood is honest.Take the effort to understand what it has to tell you before you try to change it.

View Nelly's profile


4 posts in 2401 days

#2 posted 07-22-2012 03:45 AM

Yes – they are dh sashes. They came out of my neighbor’s house. I appreciate your feedback on the project.



View BentheViking's profile


1782 posts in 2586 days

#3 posted 07-22-2012 01:29 PM

I’d use wood to try and fill those grooves. Maybe glue a dowel on edge and then plane smooth?

Which part of the window is lead? Be careful handling that stuff. I’d be careful with regularly handling something made from lead.

-- It's made of wood. Real sturdy.--Chubbs Peterson

View HalDougherty's profile


1820 posts in 3259 days

#4 posted 07-22-2012 02:21 PM

Leaded glass doesn’t expose you to metallic lead. Fine crystal is made from leaded glass. Handling solid lead also doesn’t expose you to anything that would end up inside your body unless you get shot with it. Even lead based paint won’t hurt you unless you either chew on a post painted with it or you sand it into fine dust and breath it. However it doesn’t take very many parts/billion in your brain cells to cause you to spout politics here and there or even run for office.

-- Hal, Tennessee

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