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A Do-It-Yourself Molding Machine

Make a custom molding cutter to match the profile of old sash or other damaged trim.

By David Gibney Issue 161
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In the February/March 2004 issue of Fine Homebuilding (#161), restoration carpenter David Gibney explains his process of restoring and reglazing old double-hung windows. Here he describes a unique solution to the challenge of duplicating a sash part that’s beyond repair.

A single-bladed molding head cutter (Sears Craftsman; 800-349-4358; www.sears.com) is an inexpensive, but very effective tool for making sash repairs. This tool comes with a variety of profiles, one of which is a blank cutter blade that can be used like a planer or custom-ground to replicate an odd profile.

1. Installing the custom-made cutterhead. 2. Tracing the profile onto a blank cutter.

To transfer the profile of a damaged sash part, such as the muntin shown in the photo above left, I first have to put a 35° angle on the end of the muntin (this equals the cutting angle of the rotating blade). Then I use a can of spray paint to trace the profile onto the face of the blade (photo above right).

3. Grinding the profile roughly to shape. 4. Fine-tuning the profile with a small, round file.

It often takes a variety of bench grinding wheels, Dremel bits (800-437-3635; www.dremel.com) and hand files to carve out the correct profile, but so far I’ve been able to replicate any part of any window sash that I couldn’t get any other way.

David Gibney is a restoration contractor in Smithsburg, Maryland.

Photos: Tom O’Brien

Fine Homebuilding Recommended Products

Fine Homebuilding receives a commission for items purchased through links on this site, including Amazon Associates and other affiliate advertising programs.

Milwaukee 18v Cordless Reciprocating Saw (2720)

This is a great quick-cutting saw with a brushless motor, an LED light, and a handy folding rafter hook.
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Festool Cordless Track Saw (TSC 55 KeB-F)

The Festool Cordless Track Saw is a powerful, smooth tool with reliable, high-friction strips and a semi-transparent splinter guard.
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Large-Capacity Lightweight Miter Saw

This very capable miter saw weighs less than 30 lbs. and can cut a 2x12 @ 90 deg. and a 2x8 @ 45 deg. Precise cutting and smooth-adjusting controls make it a pleasure to use.
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Previous: Fit New Sashes in Old Jambs Next: Flashing for Old Windows

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Choosing Windows
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Installing Windows In New Walls
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