#ORDER CUSTOM WINDOW SCREENS WINDOWS#

It consists of setting the ends of the screen on boards about an inch high and then clamping the unit in the middle. I learned the process in this sequence from non-other than Tom Silva. With the basic frame built, I added the screen. I obviously got that step out of order when filming this build. I also add the 7-degree bevel to the bottom of the screen frame to accommodate the pitch of the window sill. With the assembly primed, I applied two coats of an exterior-grade trim.Ī step that I typically do before the finish coat is dry-fit the frame in the window opening and then trim it to fit if necessary. I let the assembly dry for about an hour before giving the corners a quick sand to remove any imperfections and then primed any remaining exposed wood. Because these screens will be painted and only exposed to the elements for a few months a year, the exterior-grade tenons did not feel necessary for this application. Festool offers Sipo Mahogany for outdoor applications. Once the mortises were cut, I dry-fitted everything first and then proceeded to glue-up. I considered alternative methods including pocket screws but I did not want to mess around with the additional steps of filling the pocket holes. Given the time it takes to make, the repeatability, and the overall strength, this joint is tough to beat. I chose to use the Festool Domino system here because of its speed and repeatability. Next, I laid the frame out on my workbench and began marking the location for the floating tenons. I then cleaned up the edges with 120 Grit sandpaper. The stiles and top rail are 2″ wide, while the bottom rail is 2-3/4″ wide. I cut the stiles and rails out of 5/4×6, then I ripped the pieces on the table saw. I used the existing screen frames as a reference for size and milled the stock first. For the larger windows, which are 48″ wide, I went with vertical grain Douglas Fir and a joinery technique that Tom Silva used on this screen door build. I chose to rebuild them using 5/4″ pre-primed finger-jointed stock that’s suitable for exterior use.

On top of that, because the screens were joined using metal corrugated fasteners, they have not held up well. They are all made out of 3/4″ stock and include spacers to fill the gap where the locks register to hold them in place. Most of the screens that came with the house are torn and tattered.

#ORDER CUSTOM WINDOW SCREENS WINDOWS#

Given the time of year, on top of the list is getting window screens in as many windows as possible. In the meantime, I’m chipping away at projects where my experience as a carpenter can be put to good use on the weekends. It’s all too much for us to handle on our own so we are in the process of bidding out contractors to help. On the list are a lot of exterior projects that include residing (to replace the work shown here which was done by a former owner) and a complete top-to-bottom paint job. We recently purchased an old two-family that is in desperate need of repair.

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