Installing Replacement Window Sashes

Installing Replacement Sashes

This is a way to make an old drafty window behave like a new, energy-efficient model -- without changing its looks in any way. Also called jamb liner kits, replacement sashes are available in wood or vinyl. The liner on either side is vinyl but is barely visible when the sashes are installed.

To buy replacement sashes that fit snugly, measure the width of the window -- from jamb to jamb -- at the top, middle, and bottom. Use the shortest measurement. For the height, measure from the top jamb to the point where the lower sash meets the sill on the outside. Check that the frame is straight, square, level, and free of twist.

Prestart Checklist

Time
About 3 hours to remove old sashes and install replacement sashes with liners

Tools
Flat pry bar, chisel, framing square, screwdriver, drill, tape measure, angle finder (see Step 1), hammer, tin snips

Skills
Measuring accurately, removing trim pieces, stuffing insulation, caulking, assembling pieces

Prep
Follow manufacturer's instructions for measuring and installing.

Materials
Replacement sash kit, caulk

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Replacement Sash Kit

A typical kit includes two liners for the sides and one for the top. Spacing pieces allow you to make up the difference when the fit is loose. Some liners attach with screws, others use brackets (see Steps).

Step 1

Use a framing square to make sure the frame is square. It is important that the bottom edge of the bottom sash matches the bevel of the sill. This angle is usually 14 degrees. Use an angle finder, as shown.

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Step 2

Remove the inside stops. Use a putty knife or chisel, then a pry bar to remove the stop, holding the lower sash in place.

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Step 3

Lift the lower sash up and outward. Use tin snips to cut the cord or chain on each side. Remove the screws holding the cord pulleys and pry out the pulleys.

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Step 4

Use pliers or a chisel to remove the parting stop (it will not be reused). If painted, score the stop where it meets the jamb before removal. Pull the top sash down, cut its cord or chain, and remove.

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Step 5

Install the liner bracket clips as instructed by the manufacturer. Measure to make sure the clips are equidistant from the corresponding clips on the opposite jamb.

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Step 6

Snap the liners onto the bracket clips, working from the top down. If the liners do not snap in easily, adjust the clips by carefully bending them with a screwdriver or putty knife.

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Step 7

Cut the replacement head parting stop so it is the same size as the width of the upper sash. Press it into place, making sure the weatherstripping faces outward. Fasten it with the finishing nails provided with the kit. Install the filler piece that covers the head jamb.

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Step 8

Install the top sash. For a tilt-out sash, slip the sash cam pivots into the liner control slots. Push the bottom into place and test for easy operation and a tight fit all around. Adjust the side jambs as needed and install the bottom sash. Replace the stop molding.

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