Making a New Metal Screen Sash

This story shows you how to make a new metal screen sash

Screen and Storm Window Repairs

Metal storm and screen windows are frequent troublemakers, partly because they are often of poor quality and may have been hastily installed. You can sometimes -- but not always -- purchase replacement parts; manufacturers are often regional and may be out of business. For a tighter seal consider installing better-quality storms.

Prestart Checklist

1 or 2 hours to make most repairs

Hammer, tape measure, hacksaw and miter box, spline roller

General carpentry skills

Remove and inspect storm sashes. Contact manufacturers for parts as needed.

Screening and glass as needed, exterior wood glue or polyurethane glue, dowels, finish nails

Making a new metal screen sash: Step 1

Buy a screen frame kit from a hardware store or home center. Use a hacksaw to cut the pieces to length, taking into account the width of the plastic corner pieces.

Making a new metal screen sash: Step 2

Assemble the frame by slipping the corner pieces into one piece, then sliding the next piece onto the corner piece.

Making a new metal screen sash: Step 3

Install screening using a spline roller.

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