I need some advice on how best to trim a pair of inswing French casement window sash with arched tops in my 1920’s house. The sash apparently have swelled in size or the opening has shifted over the years such that the sash are too tight to close. It appears that they were trimmed in the center at some point in the past but because they have interlocking metal weatherstrip on the straight edges in the center, trimming more there will require removing and replacing the weatherstrip. Also, there is an interior beaded detail on the sash face in the center that would be lost with more trimming there. Can anyone give me advice on trimming the sash on the hinged sides with the arched tops? Would it make sense to use a belt sander around the arched edge? I am thinking I need to trim just under 1/8″ on each side. Any thoughts would be greatly appreciated.
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Trace the window onto a piece of ply or mdf to make a template. Then you can offset the template to you desired size and use a pattern bit ( bottom bearing router bit) to trim it.