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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 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:

Step 1.

Mark off a 45-degree angle near one end of the material.

Window Framing Example

Step 2.

Mark off a distance equal to one side of the opening being sure to mark on the long side.

DIY Framing Windows

Step 3.

Cut another 45-degree angle so the piece looks like the side of a picture frame.

How to Cut Metal 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.

Connecting Metal Window Frames

Step 5.

Insert the remaining 2 corner braces into the last side and attach it to the frame.

Step 6.

Install the screen fabric as described in the section on Replacing Screens on Aluminum Frame.

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