Time: 16 hours over two days.
Difficulty Rating: This project rates a 4 out of 5 on the Weekend Handyman difficulty scale.Materials:
For Removing Window and Frame --
Safety glasses
Ladder
Utility knife
Pry bar
Hammer
Safety goggles
Gloves
Reciprocating saw
For Framing Rough Opening --
Safety glasses
Ladder
Tape measure
2" x 4" pieces
Safety glasses
Impulse framing nailer
1" x 4" pieces
Miter saw
For Installing the New Window --
Safety glasses
Ladder
Utility knife
Pan flashing
Flashing tape
Self-adhesive sealing tape
House wrap
Caulk gun
100-percent silicone caulk
Minimal expanding foam insulation
Hammer stapler
1-1/2" galvanized roofing nails
Shims
Aluminum drip cap
For Installing the Window Insert --
Safety glasses
Ladder
Pry bar
Shims
2' and 4' levels
Tape measure
2-1/2" screws
Silicone
Insulating foam
1x material
Impulse nailer
Paint
Paintbrush
Removing the Old WindowUnscrew and pry out the old storm windows. Take care not to shatter the glass.Tip: Whenever you're doing a project that will stir up lots of dirt and debris, it's a great idea to rent a dumpster. A medium size yard dumpster rents for approximately $125, and be check with your local rental company for rental periods.
Disassemble as much of the windows as possible (figure A). While cutting out the weights, be sure to hold on to the sash or it can fall and shatter.If the upper sashes are painted shut cut them loose with a utility knife. Note: Take your time when working around old glass and be sure to wear eye and hand protection.
Cut the silicone bead that secures the casing to the exterior siding (figure B). Use a reciprocating saw to cut out the old frame.Tip: Cut at an angle rather than straight across. This will make it easier to push the pieces out.
Remove all the old casing around the exterior frame.
Framing In the Rough Opening- First, be sure to clean the rough opening well -- and note that a heavy-duty vacuum can assist with this chore.
- Measure the windows and frame in the opening with 2 x 4's.
- Place the boards on the top (figure C) and the bottom first, then put in side boards. That way you'll get more structural support out of you framing.
- To fill the space between the new framing and the sheathing, use 1 x 4's ripped to fit the gap (figure D).
After a day of work the rough opening is ready for the installation of the new window in the next segment.
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