How to Make an Aluminum Frame Window Screen

Its easy to make a window screen of almost any size. This video show's you how to do it starting with an aluminum screen frame kit, and a roll of screen of appropriate size. You’ll also need a marking pen and tape measure, a square, a hack saw, a screen spline roller, scissors or sharp knife, and a broad flat screwdriver. INSTRUCTIONS Measure the opening to determining the size of the screen needed. Subtract 1-1/2” from both the width and height of your measurements. These are the lengths for cutting the frame four pieces. Cut two pieces to each of the two lengths. Mark the frame sections with these measurements. Use a square to draw a line that will help guide your cut. Its easier to cut these pieces if you clamp them to the edge of a table, or use a vice if you have one. Layout your components in the order of assembly, the spline grooves facing upward and toward the interior of the screen. First assemble the short rails. Install the retainer springs and then insert corner connectors. The pull tap should snap into the groove on the side opposite the end with the retainer springs. Now attach the short rails to the long rails. Cut a length of screen material several inches longer than the frame. To install the screen material, align the weave along one of the short edges of the frame. Starting at one end, place the spline over the groove and press it into the groove with the spline roller. Firm pressure is required, but you don’t need to get it completely down on the first pass. You can always roll over it a second or third time to seat it. Now secure the opposite end. This time align the weave by sighting down the long edge of the frame. As you seat the spline use your opposite hand to gently tension the screen material ensuring that it is taut across the surface. Use the tip of a sharp knife to cut off the extra length of spline. Now you simply need to install the spline on both long edges of the screen. After cutting off the excess spline, press all the ends firmly down into the corners with a flat screwdriver. Use a sharp knife to cut off the excess screen. Insert the blade through the material and slide it along the surface of the frame. That’s all there is to it!