Custom Window Screens

Tools:

table saw
miter saw
router
power sander
pocket hole cutter
power drill
pocket hole bit
square head bit
Phillips-head screwdriver
spline roller
utility knife
clamps
hammer
comination square
tape measure
safety glasses
scissors

1. Begin by measuring the dimensions of the existing screen frames (figure A). It helps to build a prototype frame on a smaller scale, and write the dimensions onto the corresponding parts of the prototype.

2. First cut the boards to the correct length, then use the table saw to "rip" them to the correct width. When using power tools remember to follow instructions, wear safety glasses and use blade guards and push tools to keep hands well away from blades (figure B).

3. Test fit pieces to ensure they are cut to the correct dimensions.

4. Now use the pocket hole cutter to join pieces (figure C). Line up a board and lock it into place in the pocket hole cutter, and use the pocket hole drill bit to drill precise, angled holes into the boards (figure D).

5. Drill two holes in the 2-inch wide boards that form the perimeter of the frame , and drill one pocket hole in each end of the 1-inch boards used as interior framing members.

6. Once all pocket holes are drilled, set pieces out on flat surface as they will be joined.

7. Drill screws into pocket holes joining all the main frame pieces.

8. Clamp frame securely to a work surface, and use the router to cut a groove for the frame spline around the perimeter of the frame. Adjust router to go a quarter-of-an-inch deep, and use a bit that corresponds with the size of the spline being used to anchor the screen in the frame.

10. Roll screen out over frame and clamp it on one end, leaving a few inches of slack to work with. Place spline over the screen and force it into the groove by hand.

11. Next use the grooved end of the spline roller to force the spline firmly into the groove.

12. Nail trim pieces over the spline using finishing nails and cut away the excess screen (figure F).

13. Attach brackets with screws and screwdriver and you're ready to hang the screen.