Window sash construction and method and apparatus for manufacture thereof

An adjustable mold apparatus for making a window sash comprising:

• A) a mold base, said mold base having a plurality of mounting holes for accepting a lesser plurality of fasteners;
• B) a right angle mold portion permanently affixed to said mold base, said permanently affixed right angle mold portion including as a part thereof:
• i) a first mold portion, said first mold portion having:
• a) a first top wall,
• b) a first front wall,
• c) an essentially “L” shaped first recess, formed in said first top wall and said first front wall,
• d) a first mold insert groove formed in said first front wall,
• e) a first mold insert capable of sliding movement located in said first mold insert groove,
• e) a first bottom wall,
• f) a first back wall,
• h) at least a first portion of a sprue, and
• i) at least a first portion of a fan gate formed in said first top wall,
• ii) a second mold portion abutting and extending essentially at a 90° angle to said first mold portion, said second mold portion having:
• a) a second top wall,
• b) a second front wall,
• c) an essentially “L” shaped second recess, formed in said second top wall and said second front wall,
• d) a second mold insert groove formed in said second front wall,
• e) a second mold insert capable of sliding movement located in said second mold insert groove and abutting said first mold insert,
• f) a second bottom wall, and
• g) a second back wall;
• C) a third mold portion capable of adjustable attachment to said mold base, said third mold portion including:
• i) a third top wall,
• ii) a third front wall,
• iii) an essentially “L” shaped third recess formed in said third top wall and said third front wall,
• iv) a third mold insert groove formed in said third front wall,
• v) a third mold insert capable of sliding movement located in said third mold insert groove and abutting said second mold insert,
• vi) a third bottom wall, and
• vii) a third back wall;
• and
• D) a fourth mold portion capable of adjustable attachment to said mold base, said fourth mold portion including:
• i) a fourth top wall,
• ii) a fourth front wall,
• iii) an essentially “L” shaped fourth recess formed in said fourth top wall and said fourth front wall,
• iv) a fourth mold insert groove formed in said fourth front wall,
• v) a fourth mold insert capable of sliding movement located in said fourth mold insert groove and abutting contact with said first and said third mold inserts,
• vi) a fourth bottom wall, and
• vii) a fourth back wall;
• E) wherein when said first, second, third and fourth mold inserts are brought into abutting contact, they form at least a portion of a mold cavity.