Welcome to the forums! It sounds as if you have an installation problem, more than a product problem. Would it be possible for you to post a few pictures showing the out-of-squareness and other problem areas (no close ups, please, we know what they look like ). It sure would help us analyze the problem and offer good suggestions. http://www.doityourself.com/forum/el...your-post.html
It's a small home. We keep the humidity that we can from showers in the bathroom by closing the door and running the fan long after we're done. We also got a new furnace and it has helped with the humidity.. My fingernail can pull apart the wood that has taken the dark grey appearance.. I think it's wet-rotted. But I would like to fix the problem of the drastic difference in temperatures between ambient and window sill.. otherwise I think this will continue to happen..
You can probably get new sashes from the window mfg, which would probably prolong the life of the rest of the window. Same thing will likely happen in time. If you don't mind the way they look, they will probably last until the window falls apart on its own. To help prevent condensation, you could add a 3rd storm panel to the interior, which would fit in one of the flat areas of your interior trim. A glass shop could probably make these for you if you gave them the right measurements. That would probably be the cheapest option that would give you the best results. I would suggest you forget about repairing the wood, and just put the interior storm window over it and forget about it. It's possible you could get something from the mfg... under closer inspection, I see they are made by Kolbe & Kolbe Millwork.
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