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The easel holds the sash so it is easier to work on. To use the easel, lean it against a wall and set the sash on the bottom rail.
Here are the latest improvements:
- sash easel
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Resources: about $30 materials, 1 hour to make
(3) 2x4s, 2”x4”x8’, wood, construction grade, select for straightness and no twist
(4) 1”x3”x10’ wood strapping (aka furring strips, with rounded edges if available)
(6) 3” drywall screws
(18) 1 5/8” drywall screws
(6) 1 1/4” drywall screws
(1) 7/16” x 36” diameter wood dowel
(1) Varnish, quart acrylic waterborne varnish (can use leftover from bench)
(1) sheet sandpaper, 220grit
Tools: Light Carpentry tool kit, Paint kit, 1/2” diameter twist bit
1. Cut the 2x4 bottom rail and 1x3 top rail to length, make length the same as the width of the sash.
2. Begin assembly working flat on a bench or sawhorses.
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Lay the posts on edge and parallel to each other. Lay the rails square to the posts. Position the bottom rail 40” from the bottom ends of posts, or belly button height of the worker. Position the top rail 48” above the bottom rail. When screwing parts together always drill shank holes in the top part. Screw the rails onto the posts. Screw the bottom 2x4 rail on with three 3” screws at each end. Screw the top 1x3 rail on with two 1 5/8” screws at each end.
3. Flip the frame over and screw the 1x3 battens onto the rails
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with three 1 1/4” screws in the top ends and two 1 5/8” screws in the bottom end.
4. Screw the diagonal braces to the back edge of the posts
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with 1 5/8” screws, two at each end. Keep the bottom of the braces 6” away from the bottom end of the posts. Let the braces bow and lap over each other at the middle.
5. Drill a series of 1/2” holes 1 1/2” deep in the edge of each post beneath the top rail.
Space the holes 1 1/2” apart. Cut two pegs 4” long from the dowels. Make two wedges 2” wide x 14” long and drill a hole in each wedge and hang it on a screw in the side of the post.
Then set a sash on the bottom rail, stick the pegs in the holes just above the sash and lightly tap in the wedges, which hold the sash in place.
6. Apply two coats of varnish to all parts of the easel except wedges and pegs to make a smooth cleanable surface. Apply a third coat to the bottom rail. Allow each coat to dry and sand lightly between coats to smooth off nibs and whiskers.