BACK to How to Assemble K-D Storm Sash

Tools and Materials Needed
Obtain the Following Tools and Materials Before Starting Work

Storm sash can be assembled, trimmed, and sanded with basic wood-working tools.


The following tools and materials are needed:

A table or workbench at least slightly wider and longer than the assembled sash.

A bar clamp or 3/4" pipe clamp with an opening capacity at least 6" longer than the width of the sash.  For glued sash joints, 3 bar clamps are required.  For pinned sash joints, 3 clamps make the job easier and faster.

A set of 2 (or set of 6 when using 3 bar clamps) slotted wood blocks to back-up the pipe clamp jaws.  See photo of blocks with instructions on how to make them.

A long pointed stick which is used to test the squareness of the sash during assembly.  The stick should be approximately the size of a wood lath and must be slightly longer than the diagonal length of the overall glass openings.  See picture.

A sharp pencil

A hammer and nail-set to drive sash-pins

A rubber mallet

A small square and sharp utility knife to scribe ends of stiles flush with rails (Bevel square optional)

A handsaw or back-saw

A wood sanding block and 100 grit sandpaper (also 80 grit sandpaper if you do not have a block plane)

A hand or electric drill with a 3/32" drill bit for drilling sash pin holes.


Optional Tools To Make Sash Assembly Easier and Faster :

A block-plane

A bevel-square

A wood chisel

Electric sander

A putty Knife and wood filler such as plastic wood.  If none available, glazing compound can be used later to fill pin holes.

Click on images below to view at larger size.

Tools Used in Sash Assembly - Optional Tools Shown On Back Row

Tools Used in Sash Assembly - Optional Tools Shown On Back Row