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Replacing Historic Wood Sash Windows

Double hung sash window, typically found in a historic Victorian home

What are Historic wood sash windows? Sash windows can be generally broken down into three era's. First era is pre-1870, which in large part varied from region to region in the country.  Second Era of millwork (approximately 1870 to 1960), was a time of national standardization in the U.S. millwork industry. This was the time when most of the homes were built and the type of wood sashes we reproduce. In San Luis Obispo County as well as Santa Barbara County many of the homes built in that era all have double-hung sash windows. The sash sticking, as it is referred to, has the same profile everywhere and the sash horns are generally very similar in profile, however, I do notice minor differences in those depending on the year the house was built.

This Sash Horn Profile is more commonly found in England

In the last several decades, there has been a proliferation of Historic wood sash windows being replaced by modern vinyl windows. There are a number of reasons for this trend, but one of the major ones is that vinyl windows are cheaper upfront and easier to find and source. Another big reason for the push to vinyl is the use of double-paned glass, which is more energy efficient.

It is always sad to see a beautiful Victorian home with a few new vinyl windows whilst the remaining wooden sashes in the remaining windows hang on. The air-tight and easy operation of a brand new window is one appeal for replacing your historic windows with their modern counterpart, but if you consider all the variables the choice to go with modern vinyl is not so clear.

Vinyl windows have a lifespan and after that lifespan they cannot be rehabbed, refinished, repaired or fixed, they must be completely removed and the entire window assembly must be reinstalled.

Granted the lifespan of an average vinyl window is not that short 20-30 years it is still not nearly as long as a historic sash window that is properly maintained. A wood sash window can easily get to 100 years if it is painted regularly, cleaned, and maintained.

Also, one major benefit of having wood sash windows is that they were made to be worked on, much like the cars of a time past. When you have a rotting bottom rail on a sash window you can remake the sash, pull out the old one, and install it without having to tear into the entire window opening.

This particular sash is the original from the 1870's. 150 years old!

Just imagine for a moment walking down a historic part of town where elaborate and intricate millwork of the Victorian era was everywhere but instead of seeing the beautiful horns and millwork or the era on the windows every window was a like a misfitting plastic piece in beautiful sculpture of wood. I might be a little biased in this area but replacing all the historic sash windows with vinyl windows would ruin the entire feel of that historic legacy, while it might not be noticed on just a few windows here and there, it would quickly become an eyesore if it was adopted as the default everywhere

If you are unsure about what era your home's windows are from and need a little bit of guidance on what kind of options there are in regard to fixing, rehabbing, or replacing, feel free to contact us here.

detailed drawing of a double hung sash window

What We Do

  • Second Era Sash: We reproduce sash from the Second Era, which is typically 1-1/8" or 1-3/8" thick and features standardized profiles like the ogee #105.

What We Don’t Do

  • First Era Sash: We do not reproduce sash from the pre-Civil War era (First Era), as these were handcrafted and unique to specific regions or builders.

Wood vs Vinyl

1. Materials

Historic Double-Hung Sash Windows

  • Wood: Typically made from old-growth timber like pine, fir, or cedar, which is durable and can last for centuries if properly maintained.
  • Glass: Single-pane glass was common, often with divided lights (small panes separated by muntins).
  • Hardware: Brass or iron weights, pulleys, and locks were used for operation and security.
historic double hung sash window, both the bottom and top sash are replacements
Two wooden sashes made and reinstalled in the original frame

2. Construction

Historic Double-Hung Sash Windows

  • Craftsmanship: Built with mortise-and-tenon joints, which are strong and durable.
  • Design: Often feature intricate details like molded sash bars, decorative trim, and custom profiles.
  • Operation: Use a counterbalance system with weights and pulleys hidden in the window frame.

Modern Vinyl Replacement Windows

  • Manufacturing: Mass-produced using extrusion molds, making them uniform but less unique.
  • Design: Simpler, with fewer decorative elements. Divided lights are often simulated with grilles between glass panes.
  • Operation: Use modern mechanisms like tilt-in sashes for easy cleaning and maintenance.

3. Aesthetics

Historic Double-Hung Sash Windows

  • Charm: Add character and authenticity to historic homes with their traditional design and craftsmanship.
  • Customization: Can be tailored to match the original architectural style of the building.
  • Divided Lights: True divided lights (individual panes of glass) create an authentic historic look.

Modern Vinyl Replacement Windows

  • Uniformity: Offer a clean, modern look but may lack the charm and character of historic windows.
  • Simulated Details: Divided lights are often faux (grilles between panes), which can look less authentic up close.
  • Color Options: Vinyl windows come in a variety of colors, but the finish may not replicate the depth and texture of painted wood.
Screenshot

4. Energy Efficiency

Historic Double-Hung Sash Windows
Classic and full of character, historic double-hung sash windows add timeless charm to a home. However, they do have some drawbacks when it comes to energy efficiency. Since many of these older windows have single-pane glass, they don’t provide much insulation, making it harder to keep warm in winter or cool in summer. Drafts can also be an issue, especially if the windows have gaps or worn-out weatherstripping, leading to air leaks.

But don’t worry—there are ways to improve them without losing their historic appeal! Adding storm windows, replacing weatherstripping, or even using secondary glazing can help boost their energy efficiency while keeping their vintage look intact.


5. Maintenance

Historic Double-Hung Sash Windows

When choosing between historic double-hung sash windows and modern vinyl replacements, there are a lot of factors to consider—especially when it comes to maintenance, cost, and environmental impact.

High Maintenance: These windows need a little extra love—regular painting, sealing, and repairs are necessary to prevent rot and decay. But with the right care, they can last for generations.

Restoration: Restoring old windows can be a labor-intensive process, but it’s worth it to maintain the character and authenticity of a historic home. Plus, properly restored wood windows can last for centuries!

Cost: The upfront expense of restoring or replicating historic windows can be high due to the craftsmanship involved. However, they add long-term value, enhancing both the home’s historic appeal and resale potential.

Environmental Impact: From a sustainability standpoint, restoring historic windows is a win. Instead of sending old materials to a landfill, you’re preserving what’s already there and reducing the need for new manufacturing. The "embodied energy" in the original materials is retained, making this a more eco-friendly choice.


Modern Vinyl Replacement Windows

Low Maintenance: One of the biggest selling points of vinyl windows is that they’re easy to care for. They resist rot, insects, and weathering—no painting or sealing required.

Lifespan & Replacement: Vinyl windows typically last 20-30 years, but when they fail, they usually need to be replaced entirely rather than repaired.

Cost: Vinyl windows are generally more affordable upfront because they’re mass-produced. However, they don’t always add the same long-term value—especially in historic homes where they might detract from the architectural integrity.

Environmental Impact: While vinyl windows are convenient, their production relies on fossil fuels and chemicals, which can have environmental consequences. Plus, they’re not biodegradable, meaning they contribute to landfill waste once they’re replaced.


At the end of the day, it comes down to priorities. If you value authenticity, durability, and sustainability, historic wood windows might be the way to go. If you’re looking for a low-maintenance, budget-friendly option, modern vinyl replacements could be a better fit. Either way, knowing the trade-offs can help you make the best choice for your home!

Get in contact and find out about replacing a sash in your window

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