Repair or Replace?
When fixing up an old house you can rest assured that the windows will need some major attention, and you will probably find yourself dealing with the question of whether to repair the existing windows or just replace them. There definitely are benefits to replacing them, including the improved energy efficiency and the time saved not having to repair the old ones. But if your project leans more toward "restoration" than "renovation" and you're a glutton for punishment like I am, then you'll want to do what I'm doing... restore them. So let's get started!
While most of the windows on LMV are in respectable shape and can be dealt with in place, several - like the two large windows we are moving from one end of the kitchen wing to the other since we are flipping the kitchen - are rotted to the point where they have to be removed to be restored. This photo from 1942 shows window flower boxes on these windows (windows on the far right wing in the photo above). The windows on the left wing are rotten as well. Those in the center are still in good shape. It's very possible that watering those flowers over the years had an impact on the integrity of these sills.
The first step was to inspect the windows. On the back side of the jambs was an imprint... Curtis 1866. I did some research and found out that our windows are the "Silentite" window made by the Curtis Company in Clinton, Iowa. These windows have "weather-stripping" built into the design of the window to provide a better seal. I even found information on how to remove the "Silentite" windows from the frame! Turns out you have to remove 2 screws on one side of a sash and slide the copper weather stripping up and out of its slot to be able to slide the window out of its groove. By the way, Curtis went out of business in 1966 when their plant got flooded. With the growing competition from cheaper windows they didn't resume operation after the flood.
Next I disassembled the windows to identify the pieces that would need to be replicated. It's obvious that the folks at Curtis were craftsmen and took great pride in their work. Each piece of the window is cut with contour so that the pieces "lock" together, making a very sturdy window.
When disassembling the windows I found that the sash locks were all painted over and virtually unusable. I decided to clean one up to see if it was salvageable. They are definitely better made than new locks, and the patina is great. So we'll go to the trouble to remove the paint and clean these up and give them new life!
The next step in this process was to replicate all of the parts that were rotten beyond use. It took quite a bit of effort using a table saw with regular and dado blades, but I eventually was happy with my replicated parts and was able to then reassemble the frame.
A coat of Sherwin Williams best oil primer and this one is ready to go!
I have a history of tackling big projects, but this is certainly the biggest elephant I've ever tried to eat! I know that when LMV is restored it will be like all of this hard work never happened, and most people won't have a clue (unless they've seen this web site!), but I'll know. When I walk around LMV in future days I'll remember every rotten floor joist that we replaced, every piece of walnut flooring that we painstakingly pulled up and reinstalled, and every piece of wood that was cut to repair these windows. Most may think us crazy to be saving LMV. I consider us blessed.