Has anyone here tackled making window sash with a hand-tool approach? I've seen the "Simple sash" episode of the Woodwrights shop (from season 31), and it's convinced me it's something I could possibly do with enough effort. Could double panes be obtained in the sizes to fit in divided sash, and could it be installed in traditional wooden sash, if some planning was made ahead during construction? (I would assume rabbets would need to be larger, etc.; but I have no idea if those types of panes can be glazed into place.)
Anyone have recommendations of where to go for more information? Printed material is the most preferable, I guess.
A beginning web search really just turns up information geared to the modern window factory, and a bit for the powertool-centric workshop. As much as I enjoy working by hand, a lot of the reason I do so is lack of access to power tools or the space to use them. If I was going to replace all seven windows (we only own the upper story of a house built through the 1800's) I'd probably try and get access to power tools to speed everything along.
This is really just an idea in the back of my head, more than anything else. I doubt this would be an economical way to replace windows. If nothing else, though, we've got one window where the lower sash is not original, slightly damaged, and not the best match for the upper sash or the rest of the room; replacing just the lower sash would be nice. And the two poorly-installed aluminum windows in the back room would be nice to replace. I think more than anything I'm just curious.