DIY Network

Urban Conversions (Pt. 1 of 4): Installing New Windows From "Kitchen Renovations" episode DKTN-305

	Host Paul Ryan and our homeowner (Erica) take an old 1920s restaurant kitchen that had been empty for years ...
	and turn it into an eye popper ...
	without losing its sense of history.

Materials:

For Window Replacement--

screwdriver
hammer
seven-in-one tool
utility knife
pry bar
insulation
table saw
impulse nailer
level
shims
screw gun
2-1/2" screws
chisel
minimally expanding foam

For Erecting Steel Stud Wall--

1/2" Hammer drill
5/16" carbide-tipped masonry bit
steel studs and track
perma-grip anchors 1-1/4"
hammer
safety glasses
ear protection
gloves
tape measure
circular saw
diamond-tipped masonry blade
metal snips
screw gun
self-tapping sheet metal screws
carpenter's square

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	Figure A
	Figure B
	Figure C
	Figure D
	Figure E
	Figure F

With the window cavities now emptied, we can insulate the window pockets and dry fit the new insert windows. After extension jambs are added to take up the gap, the window is leveled, shimmed, and tacked into place.

1. The pulley protrudes and will get in the way of the new insert windows, so you need to remove them (figure A).

2. You don't want air to enter through the weight pocket, so add some loose insulation (figure B).

   Safety Tip: Always wear a mask and gloves when handling loose insulation.

3. Set the new window in and use a screw to temporarily hold it in place.

4. In old buildings, the walls are usually thicker than the windows, but you can fix the gap by nailing extension jambs to the sides of the windows (figure C). Be careful not to nail into the jamb liner because that could cause the window to break.

   Note: Window companies can precut window jambs for you.

5. After you put the window back in, use the level and if the window is out of level, add shims (figure D) until you get the sashes perfectly straight.

6. Use 2-1/2" screws to fasten the jamb liner to the window frame (figure E).

7. Trim the shims down with a sharp chisel and a hammer.

8. Use spray foam insulation to fill the space between the window and surrounding frame . With minimally expanding foam, you normally have to hold the spray can upside down (figure F) to prevent compressed air from escaping.

   Note: Overfilling the cavity with insulation can cause the window to bow or even break.

9. After insulating, reattach the stops and nail them in place.

In the next episode (Pt. 2 of 4), you'll see a raw space that was once a historic restaurant start to transform into a finished kitchen as we install new flat-packed cabinets that are very affordable. We show you how to construct a table that is perfect for an island work space or to use for dining.

RESOURCES :

Taunton's Build Like a Pro: Windows and Doors: Expert Advice from Start to Finish
1561584835
Scott McBride
(April 2002)
To order this title from Amazon, click here.
Taunton Press

Terrazzo Floor Restoration
Vic International
PO Box 12310
Knoxville, TN 37912
Phone: 888-342-5842

Insert Windows
Brand name: Architect Series Precision
Where available: Pella Window Scraping Centers or the website, link below.
Pella Windows & Doors
Website: www.pella.com

GUESTS :

Lars Peterssen
Architect
domain Architecture & Design
2748 Hennepin Ave. S.
Minneapolis, MN 55408
Phone: 612-870-7507
Website: www.domainarch.com

Tim Lesnar
Stone Restoration Expert
Classic Marble Restoration Co.
Website: www.classicmarblerestore.com