howdy folks welcome back to doing brew today we're taking doing brew on the road I've got the workshop packed up in the back of the truck and we're heading across town to help out one of my subscribers Ken contacted me a few weeks ago at Dew and brew at gmail.com with a couple of questions he's got a windowsill that seemed to be rotting on the inside he was concerned about what might be going on behind the wood in the structural members of the the window frame and so he wants to fix it of course well what it sounds like to me and some pictures he sent me it looks like a contractor before he purchased the home used MDF on the sill and maybe even the jams of his window well as condensation has collected over the years it dripped down on to the window sill it's caused it to swell anytime MDF comes in to contact with water usually it'll swell up like a sponge and that's certainly what's happening some nail heads are popping out it's pretty unsightly but again Ken's more concerned about what's going on behind the scenes the long story short as we're discussing possible solutions we started chatting about where each other lived and as it turns out he's only about 30 40 miles from me so I figured let's go ahead and do and we're on the road meet one of the subscribers personally soon what you can do to help now so hang on we'll be there in a few minutes okay hey Mike how are you I'm good welcome thank you come on out let's see what you got going on all right so Mike what I've got is when they put these new windows in it looks like they put MDF down on the baseboard here on the base of the window and as moisture accumulates in the in the winter it has swollen like this you can see on both sides and I'd like to replace that and put some proper material in there all right well what we'll do is we'll take out your your shutters first looks like a couple of screws should be pretty easy to do and then we'll see what we have to do here to do this repair hopefully we won't have to take apart your real pretty molding there what if we do that's not too terribly difficult and we'll be able to put it together back together or better or good so let's go ahead and take take your shutters off and before we get started we'll put down some protective cloth to make sure we don't damage Kent's floors so taking the shutters off was no more difficult than removing the five screws that held them in place and ken's is gonna lift that up out of the way now it's time to do a little bit of investigative drilling so we're drilling into the MDF here and you see the brown sawdust coming up now I'm gonna drill into the jamb piece and it's hard to tell since they fall away but you can see that the sawdust there is a nice yellow color so we got lucky the jamb is made out of solid pine now we're gonna work on make it a couple of cuts here to try and get the old sill out of place without damaging any of the pieces and parts under Wow so we made two cuts with a circular saw and then taking our time with the pry bar again we don't want to put too much pressure on things because we don't want to damage anything underneath the existing sill but with a little bit of patience we worked up the nails that were holding the old sill and a couple of taps of the hammer we're starting to ease it out and once again we got pretty lucky here because you can see that the casing is letting go of the sail which allows us to move it forward and you can lift it up and out of the place without damage and any of the case molding around the window real lucky there just a little general cleanup taking the old insulation out some shims and some blocks just making sure everything looks good and it doesn't look like there's any water damage in the structural members around and under the window and we'll have to be careful to remember to properly reinstall the windows sensor for the alarm once we're complete with the build now using the old sill as the template we're gonna take all of the required measurements and jot them down for use later as we transfer them to our new sill now we'll take a moment here to set up the doom brew workshop while we do that I can't had a great idea to use a pine staring thread as the new material for his his sill now the great thing about that is it comes in a 1 inch thickness 48 inches long and 12 inches deep so it's it's perfect for what we need to use it for now we're cutting it to the overall length of forty seven and a half inches and then we'll need to rip it down using the portable table saw here down to a width of 10 and the next thing we need to do is transfer the measurements from the existing sill to our new one here to accommodate the cutout for the jam on the right and left side now after I make measurements like this I like to mark with an X the piece of material I need to cut out I actually marked it in the wrong spot and thankfully Ken caught it now the best way to get the straightest cut is to use the miter saw so will will cut as much as we can with the miter saw and then the table saw and then we'll finish out with a handsaw or a jig saw and completely Hutton looking for real nice straight line we'll give our new silicic sanding started out with the 150 grit sandpaper and finished out with 180 okay now comes probably the tricky is part of our new SIL build and that is replicating the profile of the old SIL it looks like it was probably a store-bought material that was made on a shaper table it's just difficult for us to replicate using hand routers we're gonna give a shot Ken just completed the setup on his router to get the depth just right on a half inch roundover bit that'll be the first first pass we make with the router okay next up is a half inch coat bit that's on the underside of the sill again we use the old sill as a template did a couple of practice cuts and it looks like Ken has got that just right and now we get to a difficult part the existing sill just below the round over is a full round over not a half that's not possible for us to do using a handheld router that's that's shaper table work we're gonna go ahead and use the sander to roll over that sharp edge and then finish up with a sanding block and believe it or not we were able to get really close to the original profile certainly close enough that Ken was real pleased with it okay we're getting near to the end of our millwork the last thing we need to do is cut a rabbet along the backside of the sill where the sill meets the window and that will allow it to set down under the window frame itself a nice clean look and cutting that 3/8 inch rabbet allows us to use the one-inch thick material while still maintaining a level sill once it's installed back into the window frame okay now just using some liquid nails to hold down the the house trap and reinstalling the previously used spacer blocks there just to provide a little bit of solid material below the cell will nail those in place with some crown staples reinstall our insulation and we're getting near to done on this one folks will install some liquid nails on the base support for our sill just to provide a little extra grab and then our sill will slide right back into place the one piece of millwork we didn't show you was that little notch we had to cut out to accommodate the trim piece that actually holds the window in place very simple little square cut and a couple of taps just with the fist is all it takes to get this piece in place and once it's in place boy it it really looked nice look nice and you've it was really tight real happy with it so then we'll use a couple of two and quarter inch 16 gauge finished nails - just just hold it in place that's not going anywhere of it that provides the syllable extra security and then we'll start the work with the spackling on the nail heads and then right along where the new sill aligns with the jamb although our cuts were really good this time and the the gap there is is very very small but we want to take the time to fill even that small gap will sand it real nice and smooth so that after we do our coats of primer and finish coats it'll just look beautiful and seamless as a do & Brew subscriber ken's real familiar with how we like to finish trim work off from the dew and brew workshop so he's gonna fill in everything and make it look nice and he'll take care of doing the priming and finish coats overall it looks really nice looks like Kent's got a couple of brews for us to enjoy been a while since I've done a beer review but he got again Sam Adams winter lager you call it lager I call it like I see winner yeah all right so how many other windows do you have like this about hey good luck with that Thanks that's good Sam Adams winter lager not bad or lacquer all right wait thanks a lot folks we'll see you next time I'm doing room hey a huge thanks to Ken for opening up his home to the Dew and brew production crew it was great working with Ken this project was a lot of fun to complete and hopefully help Ken out a little bit as well if you have any questions you can always email me or leave comments or questions in the comment section please leave me a thumbs up if you liked the video and I'm always looking for new subscribers hey best of luck on your next project guys and we'll see you next time here on do and brick