Making sash
Warren in Lancaster, PA
>As someone who often makes sash, I can say that the width of the 45 sash cutter (1 1/2") makes it less useful than it could be. Most of the jobs I get are for sash in the 7/8 to 1 1/8" thick range and the Stanley cutter is useful only in the 1 1/8 to 1 1/2 range. There is also a 1 3/4 cutter available.
Making sash by hand gives a fine product but it is a lot of labor, so it pays to use flawless straight grained material. On such material I have used the Stanley cutter without tearout problems.