This is my first post here so I hope I'm posting to the correct forum. I am in the design phase for my project of building interior storm windows for my 1895 Victorian home. My plan is to make these storms very similar to the original exterior storms, but without the weep holes. I'm planning to use modern low-E glass. The windows will be between 60"-72" high and around 32" wide, with a single mutton. At this point a good finished pine is the wood of choice due to its cost and availability. This will also help match the grain with the existing old growth pine trim in the house.
My question now is how thick should I make the rails and styles? I have a Freud router bit set for making just this type of window but it requires a 1 3/8" stock. This would result in the new windows protruding from the window frame and detracting from the esthetics. It would also make the storms quite heavy and unwieldy. I think I can make due with a combination of other router bits for the copes and rabbets, but how thin can I go with the stock? Obviously I need enough thickness to produce a stable frame without so much flex that the glass would break or the glaze would move. But I also want to minimize weight and ensure a good overall look.
Any thoughts are greatly appreciated.
Thanks,
Joe