Gorillia glue FTW

Now that the paint, glazing and glass are gone it's time to see what shape the corner joints are in.

The top 2 joints are a simple type of dovetail and the bottom corners are mortise and tenon joints.
Some of the sashes had previous repair attempts that included short cut nails buried in the corners then covered over.  These areas had a lot of rust and dry rot.  I dug around the nails and pulled them out.  I cleaned out the dry rot with a carpet knife.

So about Gorilla Glue.  This stuff is cool because it follows water into areas then foams up and hardens.  You just spray water on the joints and move them back and forth to work the water in then put the gorilla glue over the joint seams and like magic it foams up and changes color.  It works great for the top joints that were just loose and didn't need rebuilding.  The parts that were so damaged that they actually came apart needed regular wood glue.  I used 2 'pipe' style long clamps and 2 corner clamps to dry the glue.  One of my secrets for this part is to use pieces of lath board (from when I removed the plaster over the weight boxes in the master bedroom) to protect the sash from damage when clamping.  Another trick is to use a lot of wax paper to prevent the glue from sticking to the workbench.

Here's a vid of me trimming the Gorilla Glue after it dries.  This takes practice to do with a razor blade without cutting yourself so be careful if you try to do what I'm showing in the video.

This is me removing the clamps.

After the clamps are removed its time to test fit the glass because sometimes the sashes change shape a bit from the gluing.  Use a wood chisel to shape the edges to make the glass fit.  You also have to clean the rock hard glazing from the glass edge.  My brother is very good at this.  The video of him cleaning glass on my youtube channel is the most watched vid I have there.

Here is how to get rock hard glazing off old glass edges so it can be reused.  Thanks Bro!