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Making an Aluminum Window Screen Frame

by Michigan State University on Apr 26, 2012

Occasionally a metal screen will fall out, be blown out or otherwise damaged beyond repair. Then there are windows, especially in older houses that are odd sizes for which a screen is desired.

Materials to make a replacement screen or odd-sized screen can be purchased at many building material or hardware stores. The framing material usually comes in lengths of 6 feet so measure the opening into which the frame must fit before you buy the material. Buy enough material to make the four sides. In addition buy a package of four corner braces. Then proceed as follows:

Window Framing Example Step 1.
Mark off a 45 degree angle near one end of the material.
DIY Framing Windows Step 2.
Mark off a distance equal to one side of the opening being sure to mark on the long side.
How to Cut Metal Frames Step 3.
Cut another 45 degree angle so the piece looks like the side of a picture frame.
Connecting Metal Window Frames Step 4.
Insert a corner brace into each end of one of the pieces and attach two more sides so you have a "U" shape.
Step 5.
Insert the remaining 2 corner braces into the last side and attach to the frame.
Step 6.
Install the screen fabric as described in the section on Replacing Screens on Aluminum Frame.

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