That sounds almost identical to what I ran into with our front parlor windows—once you start poking, the “solid” parts just collapse. I really wanted to believe the wood hardener and epoxy would buy me time, but in reality, it was just a temporary patch. I do think if you catch the rot early, those products can work, but once the core is compromised, it’s just not structurally sound anymore. It’s tough to justify the effort and cost for what amounts to a short-term fix. At least with new frames, you get some peace of mind, even if it stings the wallet.
I feel you on the wood hardener and epoxy route—it’s tempting, but once you’ve got that Swiss cheese situation inside the frame, it’s pretty much a losing battle. I’ve tried the patch-and-pray method more than a few times, hoping to squeeze another year out of old sashes. Sometimes I’d convince myself it was “good enough,” but then the next rainstorm would prove me wrong. Even the best epoxy can’t make up for a core that’s already gone soft.
One thing I’ve noticed is that folks often underestimate just how far rot can travel inside those old frames. On the outside, maybe it’s just a little flaking paint or a spongy spot, but dig in and suddenly half the stile is dust. At that point, even if you rebuild it, you’re still relying on what’s left—and that never feels great, especially if you’ve got heavy glass or double-hungs.
Out of curiosity, what do you usually end up doing with the old frames and glass? I’ve seen some people get creative—turning sashes into picture frames, cold frames for the garden, or even rustic mirrors. Other times, it’s just a trip to the dump. I try to salvage whatever hardware I can, especially if it’s brass or those old pulleys—they’re tough to find now. But most of the time, the wood’s so far gone that it’s not even worth repurposing.
Ever had any luck reusing the glass itself? I’ve tried saving panes for small greenhouse projects, but half the time they crack when I’m pulling out the glazing. Maybe there’s a trick to it I haven’t figured out yet...
Yeah, I’ve run into the same headache with old glass. Even if you’re careful, that stuff just loves to crack when you’re prying out brittle glazing. I’ve had better luck when I use a heat gun to soften things up first—still not foolproof, but it beats cold chisel work. As for the frames, I agree: once the rot sets in deep, it’s not worth the effort unless you’re just after the look for a rustic project. Hardware’s always worth saving though—those old sash locks and pulleys are way sturdier than most new stuff.
Hardware’s always worth saving though—those old sash locks and pulleys are way sturdier than most new stuff.
Couldn’t agree more on salvaging the hardware. I’ve found some of the old brass pieces polish up nicely and outlast anything from the big box stores. Heat gun trick helps, but I’ve cracked my share of panes even then... sometimes it just comes down to luck and patience.
Heat gun trick helps, but I’ve cracked my share of panes even then... sometimes it just comes down to luck and patience.
Totally get that—no matter how careful you are, old glass can be stubborn. I usually score the paint with a sharp utility knife before trying any heat, and go super slow around the edges. Sometimes it’s just not gonna cooperate, though. You’re right about patience being key. Those original brass locks really do shine up nice—worth the hassle in my book.
Brass locks really do look great once you get the grime off, but I’ve gotta admit, sometimes I wonder if the effort’s worth it for the glass itself. I’ve actually started swapping out some panes with new glass, especially on windows that get a lot of use or are in rougher shape. The old stuff has charm, but it’s so unpredictable—one wrong move and you’re sweeping up shards for days.
Have you tried using a multi-tool with a scraping blade instead of a utility knife? It feels a bit safer to me, especially on frames where the wood is already soft. That said, I still end up holding my breath every time I try to pop out a pane. Maybe I just don’t have the patience some folks do...
Curious if anyone else just gives up and goes with new glass rather than fighting with the old? Sometimes I feel like I’m cheating, but it’s less stress in the end.