DIY Network

Entryway Restoration: Side-Light Sashes From "Restoration Realities" episode DRTR-107

	The glass blocks on the entry way to this 1925 home will have to go. They're replaced with traditional sash side-lights, which are more suitable to the architectural style and historical context of the home.

In this episode of DIY's Restoration Realities, our restoration specialists help a Portland couple with a restoration of the entryway to their 1925 Dutch Colonial home. Work on restoring the original wood door is already underway. In this third segment, glass blocks on either side of the front door are replaced with traditional sash side-lights.

Materials and tools for installing sash side-lights:

Entry side lights
(Ordered custom to match the style and fit the opening. Order slightly larger and cut to fit.)
Table saw
Circular saw
Mallet and/or hammer
Cold chisel
Wide putty knife/scraper
Pry bar
Utility knife
End nippers (for removing old nails)
Putty knife
Power finish-sander
Exterior latex caulk
Exterior enamel paint
Drop cloths Air compressor & Hose
Nail gun
Pry bar
Utility knife
Hammer
Caulk gun
Paintbrushes
Polyester or epoxy resin filler
Sandpaper, various grits from 80 to 220
Exterior oil based primer
Galvanized finish nails, 8d and 10d

advertisement

Figure A

The owners felt that the glass blocks that had been installed previously at the entryway were not visually consistent with the period and architecture of the home. Instead, they wanted to replace them with more traditional side sashes (figure A). The first challenge was removing the existing glass blocks from the openings on either side of the door -- which is no easy task. Here are the basic steps for the removal and replacement of the side lights.

Removing the Glass Blocks

• Just like bricks, glass blocks are held in place by mortar. Begin by removing the trim pieces and exposing the mortar joint of the glass block.

• Use a cold chisel and hammer to break out one of the mortar joints (figure B). If you can successfully loosen the joints, you may be able to pull the blocks out one by one.

• If (as in our case) breaking the joints does not work, you may simply have to settle for the "brute strength" option -- breaking out the glass with a hammer (figure C). Begin by breaking out the top glass block, cleaning it out and working your way down the row cleaning out all the mortar all the way down.

  Figure B

  Figure C

  
  

  Figure D

• Scrape out any adhesives, additional mortar or fasteners using a paint scraper, putty knife, pry bar, pliers, and hammer.

• With the old material removed, a metal lath may be exposed. The metal lath is the surface to which the original blocks were secured (figure D). In our case, this was part of what made the removal of the glass blocks so difficult.
  

• Continue breaking out all of the blocks as well as the supports that held them (figures E and F).

  Figure E

  Figure F

  
  

• To prepare the openings for the new sidelights, the damaged wooden jambs must be cleaned up and reconditioned. Sand the newly exposed surfaces to remove all rough spots and smooth the jamb surfaces (figure G).

• In our case, an old, damaged screen-door latch (figure H) had to be filled.

  Figure G

  Figure H

  
  

  Figure I

• Use a polyester or epoxy resin filler to fill any damaged areas to the surface and cover any voids (figure I). We used a two-part wood filler to restore a smooth surface to the damaged jambs.

• Allow the filler to harden as per manufacturer's instructions. Ours required just 30 minutes to harden.

• Sand the filled in areas smooth.

• Sand the entire surface in preparation for primer.

• Paint on one coat of oil based primer and let dry.
  

  Measuring the opening for the sash.

• Prepare the new sidelight for installation by measuring the existing opening and trim to fit if necessary. In our case, we intentionally ordered the sashes slightly oversized, slightly wider and taller than the opening, then custom cut the sashes to fit.

• Measure the height and width of the opening.
  

• To cut the sashes to width, they were cut lengthwise using a table saw with fine-tooth blade (figure J).

• Then using a clamped board as edge-guide and reference, they were cut to length using a circular saw (figure K).

• Check to see if the bottom of the existing threshold is beveled. The bottom of sidelight sash will have to be beveled to match it.

  Figure J

  Figure K

  
  

  	Figure L
  	Figure M

• Set the new sidelight sash into place (figure L).

• To secure it in place, nail through the frame of the sash diagonally into the existing wood door jamb (figure M).

• Replace any interior trim at the sidelights.

• Caulk both the interior and exterior.

• Apply an enamel finish coat of paint.

• In our case, there was a slight problem in that the sashes ordered weren't the exact same thickness as the jamb, so when put in place it extended out beyond the face of the jamb just a little too far. To remedy this problem a small rabbet was cut around the edge of the sash (figure N) so that it would sit flush in the opening (figure O).
  

  	Figure N
  	Figure O

Note: This is a summary of steps included in the procedures shown in this episode of Restoration Realities. There may be variations in procedures for your particular restoration project based on the types of materials you select and the nature or extent of your particular project. Always follow proper safety precautions, and read and follow manufacturer's guidelines, diagrams and safety notices that come with materials or products that you select.

RESOURCES :

Renovating Old Houses: Bringing New Life to Vintage Homes
Author: George Nash
Publisher: Taunton Press
ISBN: 1561585351
Order this title from Amazon.com.

Renovating and Restyling Older Homes: The Professional's Guide to Maximum Value Remodeling
Author: Lawrence Dworin
Publisher: Craftsman Book Company
ISBN: 1572180293
Order this title from Amazon.com.

Selecting and Renovating an Old House: A Complete Guide
Author: United States Department of Agriculture
July 2000
Publisher: Dover Publications
ISBN: 0486409562
Order this title from Amazon.com.

GUESTS :

Bo Sullivan, restoration parts specialist
Rejuvenation
Portland, OR
Phone: 888-401-1900
Web site: www.rejuvenation..com