Box frames and Spiral balances

Work in progress

We have 2 similar jobs on the go right now, but there is a difference in how they operate; weights and pulleys versus spiral balances

These are single hung cedar sash windows. They will operate using a spiral balance tube on either side of the sash. The spiral balance means no weights and pulleys/ropes are needed. You can get custom made heavy duty spring balances for heavy glass up to about 36kilos.

A standard whitco spiral balance. suitable up to 14kg
Heavy duty spring balances.
An example of heavy duty balances from Schlegel. Thicker tube, custom made for specific orders. Up to 36kg.
Cedar Boxframe windows being assembled – sashes are not in.

These are box-frame sash windows being assembled. Both top and bottom sash will move up and down, using the pulleys on the side, with rope and to the weights which will be hidden on the side boxes (hence box-frame).

This is the traditional method of sash windows, but because you need to hide the weights you have more timber and less glass/view than using spiral balances.

The bigger / thicker the glass = the bigger the weights need to be – making them very heavy in some circumstances.

Convert window to french doors – wallcut

Finished Product

On Wednesday we made a wall cut and removed an aluminium window. Added a meranti doorframe with sill and pair of rebated doors.

Client will render edges and add bricks under the sill when ready (has a pipe underneath with a tiny rustleak that needs to be fixed first).

Arched meranti double doors

Finished Product, Uncategorized, Work in progress

We were sent to McLaren Vale for this job. Insurance. A flash flood had swept down the cellar and destroyed the existing doors. We made new ones, and new doorframe jambs. Installed using the existing arched doorframe head, and a few tweaks on the curves on the doors we had made at our factory.

remember you can find us on instagram – #thewindowmanSA

Colonial bars

Finished Product, Work in progress

We are making a series of cedar frames with colonial bars. They will be sent off and some of the frames will be assembled on site to make a bay window (about an hour south of Adelaide). I am also trying out a new glass cleaning product which I must say is fantastic.

Window to Sliding door conversion.

Finished Product, Uncategorized, Work in progress

We headed out an hours drive from Adelaide for this job. We removed 4 sections of a window frame (1 awning and 3 fixed panels).

added cowdroy top hung track systems on the inside and outside of the frame. Prior to coming out we had made a pair of doors and a pair of flydoors (in meranti to match).

added flydoors to external track and glass doors to internal tracking. Added rubber seals around doorstop of the glass doors for good weathersealing. Glass doors were double glazed.

this is the original window frame we were working on.
inside view of the original window (1 of the new meranti door panes is sitting against the window).

2022 Break up day!

Finished Product, Uncategorized, Work in progress

Today is the last day for the year at the window man 2022. We are taking a few weeks off with all staff back on deck next year on 23rd jan.

This year has been a difficult one with supply chains, ever upward costs in materials, difficulty in sourcing good timbers, changes to aluminium extrustion suppliers with our domestic windows and just covid randomly playing havoc. Despite all of the head winds we have had another successful year and look forward to both the break and the return for next year.

If you need anything quoted – please email it to us, George and I are still around and will receive your emails. Calling the factory probably wont get a response unless one of us happens to be in the office.

We wish all our customers and suppliers a happy and safe break.

peter – production manager – son of the boss

Factory Floor

Uncategorized

Timber continues to be a supply issue. Hard if not possible to source long lengths of certain timbers. One supplier sent me a pack list of 7 small packs.

I ordered 5 of them and he replied saying 2 had been sold already. Blink and you miss it.

Wood glue supplier has been waiting on his orders since august 21. We have bought the last he has, and will need to use a level up in glue (increase in $$$) instead once our regular glue runs out.

Laminate glass from one of our main suppliers doubled about 2 weeks ago. others have jumped by at least 25%.

as per the design of an architect. timber infill panel in white trans laminate glass
bringing in some lengths of hemlock we managed to source from a retired ex-joinery guy.

Random Work in Progress photos

Finished Product, Uncategorized, Work in progress
2 interesting jobs here. An Octagonal casement which will be double glazed. telescopic arm and catch. the windows HILL E33 are awning windows. they will have gas struts and will be installed into a food van. How cool.
just a couple of small fixed lite frames to go into someone new shed/basement set up.
4 panel sliding door being assembled. will have flydoors too.
this is american wallnut and is a job going to cremorne hotel. it will have reeded vertical glass. design by client which was a challenge to achieve.
american wallnut
this is the door that goes with the frame.

Fixed windows to actual sash window conversion

Finished Product, Work in progress

Last week we removed 2 fixed window frames (they were actually casement sashes but screwed shut). New cedar single hung sash windows installed. Directed to keep the internal aves and bullnose which makes it tricky. The original windows were 110 wide, our sashes need to slide past one another so are 140mm deep. this means a lot of on site cuts and trims to make it all work (and they had plantation shutters we had to use – which we took off after first fitting so they could paint).

Doorframe with hilite and sidelites

Finished Product
meranti doorframe. hardwood sill. sidelites and a hi lite. white translucent glass

You will see the side glazing beads are “loose”. So the client can screw the frame into the wall behind those beads, and then cover up and not have any screw marks seen. It’s not an oversight 🙂

2024 Christmas Closure

Finished Product

In a blink of a blink of an eye, the year has passed. Friday 20th will be the last day for the year, while we all take a well deserved break. For all our regular and old clients – you know who you are – BBQ at the factory as usual around midday.

We officially return 13th of jan 2025. We wish you a good christmas and new year. peter – production manager.

One of the very last jobs completed for the year, ready for pick up on friday while we fire up the bbq.

Doors

Finished Product, Work in progress
The doorframe and door on the left we installed this week, the double doors about a year ago.

A bit over a year later, we have returned to a lovely home in goolwa, adding more double doors, single doors, and internal doors we had made at the factory (10 doors total). My camera seemed to be quite blurry, so I don’t have enough photos to do it all justice.

These frames and bifolds we installed around september last year. since then they had the final coats of paint added and the lovely custom aves.
These frames and bifolds we installed around september last year. since then they had the final coats of paint added and the lovely custom aves.
A couple of the doorframes and double doors and lining installed this week. Client to be filling in the floorboards and adding aves. Still a bit of work