I'm looking for vinyl covers for wooden window trim, especially the sills.
....

Depending on what the actual problem is, the alternative is to just
repair the existing sill...just finished doing three on the old house.

It's really not that difficult presuming the bad section is other than
absolutely the whole thing in which case that almost necessitates
removing the window and rebuilding. But, in my experience, if they're
that bad the bottoms of the jambs are also gone, not just the sill.

With a straight edge on the sill that is angled to match the sill angle
so have vertical cut, the woundrous multi-tool will give a nearly smooth
and straight cut that can be cleaned up just a tad w/ block plane and
some hand work at the ends to make a glue joint surface.

I then used the biscuit joiner for alignment and glued with TB III. The
glue line is virtually invisible; I'm betting they'll last another 100
yr this way or at least much longer than I'm going to need to worry
about them...

--

On Tuesday, October 1, 2019 at 10:41:35 AM UTC-4, dpb wrote:
I'm looking for vinyl covers for wooden window trim, especially the sills.
...

Depending on what the actual problem is, the alternative is to just
repair the existing sill...just finished doing three on the old house.

It's really not that difficult presuming the bad section is other than
absolutely the whole thing in which case that almost necessitates
removing the window and rebuilding. But, in my experience, if they're
that bad the bottoms of the jambs are also gone, not just the sill.

With a straight edge on the sill that is angled to match the sill angle
so have vertical cut, the woundrous multi-tool will give a nearly smooth
and straight cut that can be cleaned up just a tad w/ block plane and
some hand work at the ends to make a glue joint surface.

I then used the biscuit joiner for alignment and glued with TB III. The
glue line is virtually invisible; I'm betting they'll last another 100
yr this way or at least much longer than I'm going to need to worry
about them...

--

The situation is this:

All of the window trim, including the sills, was wrapped in aluminum before
we bought the 60 YO house about 35 years ago.

A few years ago I replaced the original windows with vinyl and removed all
the aluminum triple track storm/screen frames. On most windows, I was able
to remove the aluminum wrap and re-install it to cover the gap left by the
removal of the triple-track frames.

However, the 8' picture window had a different type of storm window which,
when removed, left a ~2" gap between the aluminum sill wrap and the outside
face of the window. No way to slide the wrap inward like I did on the other
windows.

At the time I kludged a way to fill the gap to get me through the winter and
unfortunately it lasted way longer than I expected. That kludge is now failing
and needs to be fixed (hopefully permanently) before winter.

To be honest, I don't even know what the sill looks like under the wrap, but
based on the other sills, I'm sure it's not in the best of shape. If I can
wrap it completely and be done with it, I will. If not, I may need to go the
repair/replace route.

BTW, the sill wrap is painted to match the shutters.

Hopefully the window and door dealer that I'm going to see can bend a piece
to fit. I can't imagine why they couldn't, it's just a basic window sill. They
would have to ridiculously expensive for me not to take advantage of their
services.