DIY Network

Glass Block Installation From "DIY to the Rescue" episode DTTR-212

The old pulley-style window was an eyesore to homeowners Tara and Donovan Swick. The solution? A more contemporary glass block window to marry the couple's differing styles.

Materials:

Pry bar
Screwdriver
Electric drill
Fine tooth saw
Caulking gun
Utility knife
Rubber mallet
Tape measure
Two foot level
Glass block
Horizontal rigid track
Coped rigid track vertical spacers
Tube of glass block sealant
Finishing tool

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	Figure A
	Figure B
	Figure C
	Figure D

1. Begin by using pry bar to pull away old sashes, window trim, support (figure A), center stops, then window. Once window is removed, remove window pulleys.

2. Build a frame to fit the windows inner measurement. Once the frame is constructed, take inside measurements, then create a brace to keep the top and bottom measurements the same during the glass block installation (figure B).

3. Next, install plastic tracking inside the frame on the horizontal top and bottom and the two side pieces.

4. Cut the horizontal rigid track spacers for each course to fit inside the vertical perimeter channels. Save the short pieces.

5. Vertical spacers are supplied precut to length for use with 8" blocks. If the blocks you’re using are less than eight inches, cut spacers to size.

6. Place two glass blocks into the sill channel. Slide one block into the right jamb, and one into the left jamb. Install the remaining blocks in between the two corner blocks on this bottom row.

7. Install vertical spacers between each of the glass blocks. You may need the rubber mallet to tap the last vertical spacer into position. Inspect each joint for alignment of the spacers.

8. Place the horizontal spacer (figure C) on top of the first row of glass blocks. Cut the spacers so that the joint is at least two inches away from a vertical glass block joint.

9. Repeat this technique for each row (except the top row), remembering to always start from both sides and work inward with the glass blocks. After two rows are completed, set window upright to complete additional rows.

10. For the top row, the spacers are slid in from the front of the glass block joints. The last spacer may need to be tapped in with a rubber mallet. Add more braces to the frame.

11. Add entire frame with glass block to your existing window opening. Nail at corners at 45-degree angles to secure to window surround. Remove braces from the glass block frame.

12. Seal horizontal joints first, pulling the tube through the joint. Slightly over-fill the joint.

13. Use spoon-shaped finishing tool and push it over the joints at an angle to collect the excess sealant and seal the joint. Periodically wipe the sealant from the joint finishing tool bowl and remove any excess sealant from the block faces using finishing tool.

14. Use the same method to fill the vertical joints (figure D). Carefully work the joint intersections to create a smooth finish. Repeat this procedure to seal the opposite side of the panel.

15. Apply a bead of sealant between the channel and frame on top row of blocks.

16. Allow the sealant to cure 48 hours before putting any stress on the panel.