Custom Replacement Sash for Vintage Wood Windows

Handcrafted from appropriate wood species to match the project, with profiles and details aligned to the original design. Built to integrate with the existing frame while maintaining the overall character of the window, with options available for energy performance upgrades.

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The Accurate Alternative to Full Window Replacement

When original sash are beyond repair — or when energy performance needs to be brought to current standards without replacing the full window unit — our offers a precise, preservationappropriate solution

We duplicate the original sash in clear vertical grain fir, custom-made to fit the existing frame opening with no alteration to surrounding architecture, trim, or interior finishes. The result is a replacement that is architecturally accurate, structurally superior to vinyl or clad alternatives, and virtually indistinguishable from what was originally installed.

Homeowners, architects, contractors, and builders can specify replacement sash knowing the character, proportions, and period detail of the original building will be maintained.

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If a building was originally built with wood windows, there is no material that matches it for authenticity, repairability, or longevity. Vinyl and fiberglass replacements are designed to fit most architectural styles which means they fit none of them precisely. Clad windows have thicker sight lines, can conceal rot beneath the cladding, and cannot be maintained on an ongoing basis.

Why Vertical Grain Fir And Why Wood at All

if a building was originally built with wood windows, there is no material that matches it for authenticity, repairability, or longevity. Vinyl and fiberglass replacements are designed to fit most architectural styles which means they fit none of them precisely. Clad windows have thicker sight lines, can conceal rot beneath the cladding, and cannot be maintained on an ongoing basis.

Our sash are constructed from clear the same material used in the original construction of many historic Pacific Northwest buildings.

Stability and Durability

Straight, uniform grain patterns resist warping and twisting under temperature and humidity fluctuation. The tight grain provides the structural strength needed for high-precision joinery in sash that will be opened and closed for decades.

Natural Moisture Resistance

The vertical grain pattern minimises exposed end grain, reducing water absorption and extending the life of the wood. This is why original old-growth timber windows have survived 80– 100 years in service — and why properly fabricated VGF replacements will do the same.

Repairability

Unlike vinyl, clad, or fiberglass units, wood sash can be repaired, refinished, stained, or repainted as needed throughout their lifespan. They do not become landfill when a component fails.

Double-Hung and Casement Both to Exact Specification

Chosen Double-Hung™

The most common window type in American residential and historic commercial construction. Replacing only the sash is less invasive than a full window replacement — no disturbance to surrounding trim, siding, or interior finishes. Particularly important in historic buildings where wall and trim materials may be irreplaceable.

Chosen Casement™

Casement windows became widespread in U.S. buildings from the 1920s through the 1940s, aligning with Art Deco, Art Moderne, and International architectural styles. Replacing only the sash allows the original frame — often integral to the architectural style and period proportions — to be retained. Includes awning and hopper configurations.

we have different profiles

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Glazing Options:

Custom to Your Project. Accurate to the Original.

Glass Patterns & Sash Configurations

We reproduce virtually any glass pattern and sash configuration — including both true divided lites (TDL) and simulated divided lites (SDL). SDL configurations allow for the use of a single insulated pane with decorative muntins applied to the surface, improving thermal performance while maintaining the appearance of divided panes.

Muntin grid types available: Standard (3/8" x 1/4"), Box (3/8" x 7/16"), Flat (5/8" x 1/4"). True divided light vintage sash use OGEE style muntins.

Sash Finish

Three finish options: stain grade, primed and ready to paint, or fully painted to your specifications. Dense VGF accepts stain smoothly and evenly new sash are virtually indistinguishable from existing ones.

Moulding Profiles

Ogee and ovolo profiles available in vertical grain fir. Both profiles reflect the historical craftsmanship of vintage window construction and ensure period-appropriate replication.

Hardware

Solid brass hardware available in antique brass, polished brass, brushed nickel, polished nickel, oil-rubbed bronze, and lacquer-polished brass. Types include double-hung locks, sash lifts, casement hinges, casement arm/adjuster, casement latch, transom latch, and double-hung pulley. Window sash cord and balances also available.

Note: Hardware is supplied separately and is not pre-installed.

Modern Energy Performance in a Period-Accurate Package

Original single-pane glass carries a U-value of approximately 1.04. Our replacement sash with insulating glass units — using Solarban 60 low-E glass with argon gas fill — deliver the following performance

Glass Option	Type	Thickness	U-Value (IP)	SHGC	VT	Heat Loss Reduction	Air Leakage (cfm/ft)
Solarban® 60 IGU	Standard IGU, Argon Fill	5/8"	0.26	0.40	0.72	324 BTU/hr	0.10
LuxWall Enthermal™ + Solarban® 60	Vacuum Insulated Glass (VIG)	10mm (~3/8")	0.057	0.27	0.53	432 BTU/hr	0.10

Notes:

Solarban® 60 IGU values are based on a 5/8" insulating glass unit with 90% argon / 10% air mix.
LuxWall Enthermal™ VIG values are based on 10mm (~3/8") vacuum insulated glass.

Validated Performance

Independent testing by the University of Oregon shows sash-based energy upgrades can reduce the overall window U-value by approximately 25-30%, with full system improvements-combining sash upgrades, weatherstripping/air sealing, and wall insulation achieving up to a 61% reduction (from 0.44 to 0.17)

Designed for Historic Buildings

Our custom replacement sash systems are developed with an understanding of historic preservation requirements and the realities of working on existing buildings. Each project is evaluated individually. In many cases, this means aligning with preservation standards and maintaining original material wherever possible. In others, it may include energy performance improvements or other upgrades based on the goals of the project.

Our approach is to balance performance, durability, and the character of the original window — so the final result fits both the building and the intent of the work.

We have completed more than 40 historic preservation projects including the Oregon Supreme Court House Building, University of Oregon Gerlinger Hall, Portland Center Stage, Redmond City Hall (DeMuro Award winner), Grant High School Modernisation (DeMuro Award), and the Woodlark Hotel — both the Woodlark Building and the Cornelius Hotel, each listed on the National Register of Historic Places.

Custom Orders for Architects, Contractors, and Building Owners

Every sash order is fabricated to exact specifications. Lead time and pricing depend on configuration, quantity, and glass selection. Contact us to discuss your project requirements.

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