Making New Window Screens

Do you want to enjoy a summer breeze in your home, porch or gazebo while keeping the bugs out? Do you currently have screens with curled corners or small holes, screens that need to be replaced, but you don’t want to spend much money? Having a window company make custom window screens can be expensive. Making your own screens is a challenge, but it is not very difficult if you are well prepared.

It is possible to purchase kits with all of the supplies you need, including mesh, corners, pull tabs, springs, splines and a spline tool. You can purchase screen kits to suit your needs, whether you prefer a screen to keep out excessively strong solar rays, pets, or bugs. With the right tools and a little practice, you can make your own window screens for a fraction of the cost!

Things You'll Need:

• Tape measure and a pencil for marking
• Miter Saw or hack saw, miter box
• Aluminum screen frame material (comes in many different styles and colors. Choose what works best for your application)
• Screen Mesh (choose from aluminum, fiberglass, solar or pet screen)
• Screen spline
• Screen spline roller tool
• Corner connectors (miter or non-miter)
• Razor utility knife
• Metal screen springs
• Screen pull tabs

Step One
Select the frame style and related frame corners appropriate to your needs. For non-mitered corners you will cut the frame at 90 degrees. If you don't want the plastic corners to be visible, you would select a miter corner which fits completely inside the frame and will not be visible looking at it (like a picture frame). For miter corners you will have to cut your screen frame at 45 degree angles.

Step Two
The first step in making your custom window screens is taking good, accurate measurements. All newer vinyl windows have a channel that runs the perimeter of the window in which to accept a screen. Your measurements should be from the inside of this channel. Take a measurement for both the height and width. Remember the golden rule of measuring - check twice, cut once.

Step Three
Once you have your measurements, you are ready to cut your screen frame to the appropriate size. Measure twice and cut once to avoid mistakes. Be sure to subtract the length that the corner connectors will add from the length of the material to be cut (i.e. if the corner connectors are 1/2 inch wide, subtract 1 inch from your measurement and that's the amount of frame material you need to cut). Set up your miter saw to cut the desired length and cut away. Be sure to measure your first cut to ensure that your calculations were correct before you proceed.

Step Four
After you have your screen frame pieces cut, connect the four pieces of frame material with the corner connectors (be sure to add the metal springs to one vertical side of the screen before adding the corner connector). Test fit the screen frame in the window opening to ensure a proper fit.

Step Five
You are now ready to install the screening. The first thing to remember is to place your pull tabs in the spline channel in the frame material on the opposite side of the springs (if you don't have pull tabs, you'll get the screen in, but won't get it out!). Make sure your screen mesh is wider than your frame in order to make it easier to work with.

Start with a flat, sturdy working surface which is larger than the screen. If the frame is not laid flat, the screen will be uneven. If you are working with a large screen and intend to add a center support bar, do it at this time. Roll out enough screen mesh to cover the entire frame with a little excess on all sides.

Using a screen roller, roll the screen into the grooves while pressing it with your free hand to prevent the screen from bunching (pre-forming the screen into the grooves is not necessary if working with fiberglass screening). Next, take the rubber spline and using your roller tool, roll the spline firmly into the spline channel (your spline should be a little bigger than the channel to ensure a nice tight fit). The correct sizes of spline are shown with each of our frames. Repeat this step on all four sides.

There will be some practice involved, so don't get discouraged if you end up with something that looks more like a tuna net (too loose) or an hour glass (too tight). You can always pull the spline out and try again if you don't like the way it looks. Once you are satisfied with your final product, use your razor knife and trim any excess screen mesh for a nice, professional look. Use a screwdriver to push the screening into the corners.