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Cutting lead for sash windows

AJB Temple

AJB Temple

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I decided to have another fiddle about refining my new big sash window today. I am aiming for fingertip lightness on the sashes.

As an aside, I wish I had asked Dan about this before I started. Although the on-line advice was weigh the window sashes in situ on scales (as per my previous thread), his advice was take the sashes out and weight them separately. Lesson: listen to Dan. I learnt as I went along but it has taken time to do this job perfectly.

My in situ method gave a weight that certainly worked. However, to get fingertip lightness, with a full clean out and application of non-silicon lube, required an additional 4.22 kg on the lower sash. I was amazed, but you can now practically blow it up and down. The upper sash is the same size but needed far less lead.

Had plenty of spare lead as I bought extra just in case, having sold the load that came with the window (too damaged) and had to cut it. What a performance! There must be a better way. This was 50mm square section lead and I cut it with a large rigid frame hacksaw. It took ages. I scored all round, and turned the block regularly, and used a new blade in my old eclipse large (12" I think) hacksaw, but the cut clogged constantly and both lead and blade got quite warm. It took me almost 2 hours to cut 4 pieces neatly, file up and fit.

The factory cuts looked like a circular saw was used. Is there a method for hand cutting that I should be aware of?
 
Large teeth. If you used an 18 or more TPI blade, theres your problem.
A tree saw might be a better option next time 8-)
 
AJB Temple":sna5c397 said:
Lesson: listen to Dan.
Click to expand...

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AJB Temple":sna5c397 said:
The factory cuts looked like a circular saw was used. Is there a method for hand cutting that I should be aware of?
Click to expand...

I tend to just use the powered mitre saw, lead won't do it any harm even if it's a new blade, just clean it up thoroughly and try to prevent lead from shooting out all over the place (ideally, do it in a cardboard box or something similar!).

I haven't tried it, but a coarse disposable handsaw for wood might've been a good option.
 
Ahem....I refer the Honourable Member to my post on the first page of the "Making a sash window work" . :eusa-whistle: thread.
 
Yes. You get credit too Roger. Sorry. Dan was just firmer in telling me to be sensible. :oops:

It's a funny thing. Ignorance is inhibiting. I knew I was ignorant but didn't want to believe the solutions were simple as they looked, to me, anything but. Now I know better, but it's a case of learning.
 
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