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 materials 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. Also, buy a package of four corner braces. Then proceed as follows:
Mark off a 45-degree angle near one end of the material.
Mark off a distance equal to one side of the opening being sure to mark on the long side.
Cut another 45-degree angle so the piece looks like the side of a picture frame.
Insert a corner brace into each end of one of the pieces and attach two more sides so you have a "U" shape.
Insert the remaining 2 corner braces into the last side and attach it to the frame.
Install the screen fabric as described in the section on Replacing Screens on Aluminum Frame.
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