Repairing Sash Windows

Filed Under: DIY Outdoor, Do it yourself, Home repair, Remodeling    by: ITC

The sash (or double-hung) window was used a great deal on homes right into this century almost to the exclusion of any other type. It’s a period feature, often adding a touch of authentic charm. Unfortunately Sash windows can be very difficult to keep in good working order.

Sash windows actually consist of two separate windows – sashes is their proper name – each sliding vertically in its own channel. When both are closed, the sash in the outer channel is at the top, and the inner sash is at the bottom.

The channels are formed by three sets of beading, running round the inside of the frame. These are known (starting with the outermost one) as the outer, parting and staff beads. The outer and staff beads lie flat on the window frame, but the parting bead is fixed on its edge. The outer bead, in fact. may well form part of the frame itself; the other two are always separate pieces, nailed in place. For easy removal they should never be glued, or maintenance of the window becomes impossible.

How sashes work

Counterbalancing weights, each pair of which weighs the same as the sash they’re attached to, ensure that the sashes stay in whatever position you choose and don’t come crashing down – perhaps with such force that the glass is shattered. There’s a weight on each side of each sash, hidden in a compartment inside the frame. Each weight is attached to its sash by a cord that passes over a pulley at the top of the frame and is nailed to the side of the sash.

The drawback of sash windows is that it’s almost impossible to make them fully draught-proof. although some success can be achieved with brush-type draught excluders. The only sure way is to install secondary double glazing – the type that fits within the window reveal and is hinged to, or slides in. its own frame. You can’t attach fixed double glazing panels directly to each sash because they won’t slide past each other. And even if you could, the extra weight would throw the sashes out of balance. preventing the inner one from remaining in the open position and the outer one from remaining closed.

Minor repairs

However, many lesser faults can easily be cured if you know what to do. Often you needn’t even dismantle the window.

Hacking out and replacing old. crurnblinp putty, and renewing a cracked pane of glass, for example, are two jobs where dismantling the window is unnecessary. And if a pulley squeaks – just oil it.

You can even repair a sash corner joint that has begun to open up, provided you wedge the sash firmly in place while you’re working on it. All that’s needed is a flat, L- shaped metal plate which you can easily, buy: you just screw it across the corner. It looks a hit unsightly if left exposed; but you can conceal it by first chiseling out a shallow L-shaped recess to take it, and afterwards covering it with paint (not emulsion paint), Cellulose filler and then a top coat of paint – in that order, so that the water in the filler doesn’t rust the metal and discolor the paintwork.

Filler will also take care of minor cracks, dents and other blemishes in the wood. You can do a certain amount of redecorating, too, without removing the sashes. but you’ll find it hard to get a neat edge as you approach the concealed parts.

Major repairs

Some jobs, however, do call for taking the window to pieces – a procedure that’s far easier than it sounds. One such task is silencing a rattle; the root of the trouble in this case is that the beads are too far apart and need repositioning.

Pries off first the staff bead and then the parting bead on each side of the frame. There’s usually no need to interfere with the sections of beading at top and bottom, but you’ll have to take out the inner sash to get at the parting bead. To remove a bead, cut down the angle with a sharp knife first to break the paint seal and avoid tearing off flakes. Then push a chisel between it and the frame, as near the nails as you can, and spring it out gradually.

The various beads may well have become damaged over the years. In that case you can simply replace them with new ones, bought from a timber merchant (ask for them by their proper names, and he’ll understand). To lessen the risk of splitting, drill pilot holes for the nails oval nails are best. When re- fixing the beads, position them close enough to each sash to cure the rattle, but not too close. or you’ll bring about the second common fault: sashes which won’t slide freely, or at all.

The other and more likely reason for that. however, is a build-up of paint in the channels? You can’t just go on putting coat upon coat of paint when you redecorate them. and the only remedy when they jam is to sand or scrape off the paint where thrashes are binding, leaving room for the primer and one or two further coats that will have to be re-applied to the bare wood.

Renewing sash cords

Filed Under: Do it yourself, Home repair, Redecorating    by: ITC

Whether or not you’ve had to pause in order to repair a sash or to repaint everything, you’re now ready to carry on and fit new sash cords.

The first step is to remove the weights. To get at them, you have to take out the one or two pieces of wood covering each weight compartment — the pocket pieces. These are usually just a push fit, and you pry them out with an old chisel or screwdriver; in somecases, – however, there’s also a retaining screw. Lift out each weight, untie the cord from it, and attach it to the free end of the string, making a complete loop. If there’s rust on the weight, you can rub it off with abrasive paper at this stage. but there’s no need to paint it.

You can buy new sash cord from almost any builder’s merchant or hardware store, but ask for it by name — doesn’t just use any old cord. To fit the new cord, untie the loop of string. tic the cord to it, and use it to thread the cord over the pulley and down into the weight compartment. Then tie the cord to the weight with a strong knot. At this stage don’t try cutting the cord to the correct length — leave it too long.

Most sashes have a groove, near the top of each side, in which the cord is fixed with small galvanized round-head nails. Either nails the cord into the groove and trims off the excess, or marks the groove length on the frame and trims the cord to the mark.

Whichever you do, the weight should hang 50mm (2in) above the base of its compartment when the sash is at the top of the frame. It’s the same for each sash. Note that the cord shouldn’t be fixed right to the top of the groove, or the sash won’t run all the way up. The topmost nail should be as far down from the top as the top of the pulley is from the top of the frame opening.

After fixing the cords at both sides of the outer sash, replace the parting bead. Then repeat the whole process for the inner sash, and lastly replace it and the staff bead in position. When fixing the beads. make sure the sashes have room to slide free.

How to Build Your Own Wind Turbine

Filed Under: Crafts, Do it yourself, Electrical    by: ITC

Wind turbines can be built at home using different ways. However, all of them require the following major parts:

  1. A tower
  2. Blades
  3. An electronic control system
  4. Batteries
  5. A generator
  6. A mounting

The simplest way to start building your wind turbine is utilizing permanent magnet DC motors as power generators. Avoid going for those computer tape drive motors. The best option is the 99 volt DC motor made by Ametek. However, if you don’t get an access to it, you can go for other Ametek models which also make good generators.

Once done with fixing a decent generator, your next task is finding a hub and blades to connect to it. You can create your own blades by slicing them out of wood. However, this requires tremendous amount of effort. A more promising option is carving blades out of a PVC pipe and forming them into airfoils.

A six inch pipe that is 24 inches long is appropriate for the task. Cut the pipe lengthwise around the circumference in 4 equal pieces. Use a palm sander or a belt sander on the cut edges of the blades to give them some extra smoothing.

For the hub, select a toothed pulley that is more likely to fit easily in the motor shaft. If the pulley turns out to be smaller to bolt the blades in perfectly, you can have it fixed along with some aluminum disk after cutting it into the required size, to make a proper drilled, tapped, and bolted hub. After drilling and mounting holes in the blades, you can have them attached to your hub.

The same shop from where you purchased the PVC pipe can also provide you with vent caps that are dome shaped. These can act as the spinner to your hub. However, this is a crucial step, since some spinners are likely to spoil the effectiveness of blades.

For the mounting, connect the motor to a preferable sized piece of wood. To protect it from tough weather, make a covering out of a piece of the PVC pipe. Use a heavy aluminum piece for the tail. For free turning of the head in the wind, use 1 1/3 inch conduit for the tower and fittings of 1 inch pipe at both ends. Then, attach a 1 inch iron flange to the generator end and rivet a 10 inch iron pipe to fix into it. Pass wires from the generator through the center of the conduit unit to the tower base.

Make a U-shaped cut from a 1 inch pipe for your tower base. In its middle, assemble a Tee that is 1 ¼ inch long. Add a close nipple of 12 inch. Also add a 1 inch Tee from this nipple to the reducer.

Once you have sorted out the mechanical parts, you require fixing the electronic part of your project. This would include a couple of batteries to store the energy generated by the turbine, a secondary load where energy from turbine can be stored while batteries are full, a controller charge for running everything, and a diode that can prevent wastage of batteries while spinning the generator.

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