Reproducing double-hung windows in the United States presents a unique set of challenges, making it a relatively rare endeavor. These challenges encompass historical accuracy, material sourcing, craftsmanship, and modern building standards. Understanding these complexities is essential for those seeking to undertake such specialized projects.
Historical Accuracy and Architectural Integrity
Double-hung windows, characterized by two movable sashes that slide vertically, have been a staple in American architecture since the 18th century. Their design allows for versatile ventilation and has been integral to various architectural styles, notably during the Victorian era. Reproducing these windows requires meticulous attention to historical accuracy to maintain the architectural integrity of historic structures. This involves replicating original profiles, dimensions, and detailing, which can be intricate and labor-intensive.
Material Sourcing and Authenticity
Historic double-hung windows were predominantly crafted from old-growth timber, prized for its density and durability. Today, sourcing similar quality wood is challenging due to environmental regulations and the scarcity of such resources. This scarcity necessitates the use of alternative materials or reclaimed wood, both of which require careful selection to match the original aesthetics and performance. Ensuring authenticity in material choice is crucial for achieving a faithful reproduction.

Craftsmanship and Specialized Skills
The construction of traditional double-hung windows demands specialized craftsmanship, a skill and knowledge base set that has diminished over time with the advent of large window manufacturers automating the process of making windows from vinyl and aluminum. Another common reason that modern windows are more appealing to contractors and DIY'ers is the advent of the nailing fin. The nailing fin is pretty much how all modern vinyl and aluminum windows are installed. The ease of installation makes the job less time-consuming but this does come at a cost. I didn't pay much attention to things like windows in my younger years but as I started making and building things I started to become keenly aware that there was something missing from almost all modern housing and buildings. Then as I started to notice this more and more, and after several trips to Europe it was like a brick hit me in the forehead.
Only 5 or ten years ago I thought that the idea of form follows function was brilliant. It appealed to the minimalist in me and when you looked at the sleek, buttonless, and perfectly minimalist products Apple was producing it seemed like the obvious solution everywhere.
- Functionalism: Functionalism, a term coined by Louis Sullivan, emphasizes that a building's purpose is paramount to its design, taking precedence over beauty.
- Modernism:"Form follows function" became a guiding principle for modernist architecture, pushing back against the ornate designs of the past that often prioritized decorative elements over usability.
- Examples:
I blame a few bad decades in America for this in part because typically when people are moving from more ornate designs it is in the context of 1980's cabinetry and the other blunders that marked the 60's 70's and into the 90's
We need to be frank, the 1980's red oak veneer was as big of a mistake today as it was when it was first made. So I understand why people are drawn to the simple clean lines of Mid Centuruy Modern, or the clean tidy aesthetic of the Shaker style. I was on board, completely. Every logo, electronic device, car, and furniture design followed this trend not to mention the luxury home market.
Gone were the days of the steeply pitched roof, ornamental millwork on the porch the wonderfully charming double hung sash windows.
Another ahha moment was after I saw this video that explains how actually the form was part of the function in old window designs.
I saw a video on this talking that was titled Why Every New Building Looks The Same
It's the layers that give a home that warm and inviting feeling. By layers, I mean the shadow lines, the contrast of having elements that protrude and elements that are recessed.
Take for example this building, situated in downtown London.

Sure some people might defend it, noting how impressive it is and it still carries that modern aesthetic.
I challenge anyone who argues that this building is inviting. On the contrary even the stated goals of brutaist architecture. New brutalism is not only an architectural style; it is also a philosophical approach to architectural design, a striving to create simple, honest, and functional buildings that accommodate their purpose, inhabitants, and location.
That all sounds well and good and until you stop and think about what that means. if the philosophical approach to design is simply that form follows function, the logical progression of that statement should be applied to residential housing, on every front.
I wont lie I completely bought into this idea too. What does it truly mean for a house where form only follows function. Well for a window the form should be reduced, simplified, condensed so that if a windows job is to provide light and ventilation. Therefor it does not need casing on the outside if it can be avoided and where the glass sits relative to the outside of the house is completely irrelevant.
Just take a look at this house.

Five years ago I would have thought, "oh that so cool, it so clean and modern!"
Now when I look at a house like this and the millwork or lack there of I cant help but to imagine a whole neighborhood filled with these or similar.
While it's true that no place looks good if it has not been maintained and modern house like this will simply look like something straight out of one of those futuristic dystopian shows like Black Mirror.
One of the reasons people like clean minimalistic styles is that it does not force and impose anything on you.
This might seem like a strange statement to make but it's true. Just think about Notre Dame Cathedral, even when atheists walk inside to admire the beauty they are constrained simply by entering into the building. The building commands a deep feeling of awe wonder and humility. The same goes for residential homes and the carpentry that goes into them. The modern minimalist style is the opposite of a Notre Dame. It commands nothing out of you, nor evokes any emotion. It is like a blank slate, the iPad, iMac. Pay attention the next time you are in one of those high-density developments for condos. I have been to several in my area and they are the worst. In one of them, they purposely made all the entry doors invisible from the street or even when you are standing in the middle of the 4 or 5-story complex.
One of these complexes they built close to the freeway where I live. A few minutes of walking around the perfectly manicured property there was no sign of life or anyone living there apart from the cars in the parking lot. It had a soulless atomizing feeling, stripped of any statement, or personalization. The inhabitants of this new housing could just as easily call themselves the number of their complex.
Number 46, why was there a circular green shrubbery hanging off of your door? You know it is against the HOA policy to have anything obstructing the number of your cell I mean condo.
These places are completely devoid of any small-town charm, or community. They are designed to be slept in and have a place to prepare your meals. If you were to design a space with the purpose of fitting as many people as you can in a rather uninspiring place. then this complex dit.
This is where the modernist and minimalist aesthetic falls apart. If you drive around any suburban area where strip malls abound you could not tell one from the other. Many times they are cookie-cutter molds of the same complex or at best a Tetris version of the same building in a slightly different configuration. Windows that are flush with the outside of the building make sense as when you secure the nailing fin to the outside of a building the form of the window is simply the product of what it is supposed to do.
It's for this reason I think that saving the double-hung, wood sash window is absolutely crucial to preserve the integrity and the community spirit of neighborhoods. Another thing you see or don't see to be more accurate is children. These types of places are sterile and neutered.
The next time you are out walking notice the types of windows you see and how each house evokes an emotional response from you. Many times this is something very subtle and when asked to explain why something feels more inviting and warm we often don't have to knowledge to know why we simply are responding in the manner in which most people respond.
A home with beautiful double-hung sash windows is beautiful because of those layers. The casing, architrave, ogree molding profile, and true divided lites. They give that depth and interest as light hits them, unlike the flat windows whose sole purpose is to let light and air in or keep it out.

Everything has been stripped down to the bare need to make and secure the window and the result is a flat, boring, and neutral at best facade.
The same things that we we like or think we like are the ones that start to feel anti-human in a sense.
I know that might be hyperbole, but as an object looks streamlined and clean it is designed for the machines that make it not necessarily the people that use it. In order not to find ourselves in a world that is dominated by ugliness first we have to be able to notice and identify it. Otherwise, we remain in that state of knowing that something feels off, but never being able to put a finger on why.

Artisans capable of executing traditional window sash fabrication techniques are rare, and their services come at a premium. This scarcity contributes to the rarity of authentic double-hung window reproduction projects.
Integration with Modern Building Standards
Balancing historical accuracy with contemporary building codes and energy efficiency standards adds another layer of complexity. Modern requirements often necessitate enhancements such as insulated glazing and advanced weatherstripping, which must be integrated without compromising the window's historic character. Achieving this balance requires innovative solutions and a deep understanding of both traditional methods and modern technologies.
Cost Implications
The cumulative effect of these challenges is reflected in the cost. Custom wood window sash makers invest significant time and resources into each reproduction, leading to higher expenses compared to standard window replacements. This financial consideration often deters property owners from pursuing authentic reproductions, opting instead for more economical alternatives that may not fully capture the original's essence.
Conclusion
The rarity of double-hung window reproduction in the United States stems from a confluence of factors, including the need for historical accuracy, challenges in material sourcing, the scarcity of specialized craftsmanship, the necessity to meet modern standards, and the associated costs. Despite these obstacles, the preservation of such architectural elements is vital for maintaining the cultural and historical fabric of historic homes and buildings. Engaging professionals experienced in period-accurate window reconstruction ensures that these timeless features continue to be cherished for generations to come.