Replacing an AC Unit With a Window

Build a window sash for an opening that won't fit a standard-size window.
Related To:
HDSWT507_Windows_after_s4x3

HDSWT507_Windows_after_s4x3

There used to be an air conditioner on one side of this fireplace and an ugly aluminum window on the other side. Now there are two matching hopper-style windows

There used to be an air conditioner on one side of this fireplace and an ugly aluminum window on the other side. Now there are two matching hopper-style windows

If you can't find the right size window, make your own.

Tools and Materials:

hammer
chisels
miter saw
compressor and finish nailer
table saw
screw gun
two 10’ 2 x 4 clear Douglas fir for sashes
two 8’ x 1-3/8” wood trim
rail-and-stile bits
piano hinge
sash latches for casement
glass cut to fit
glazing compound
push points
wood glue

Steps:

HDSWT507_Windows_removing_s4x3

HDSWT507_Windows_removing_s4x3

1. Remove air conditioning unit from the wall and all related weather stripping. Repair or reconstruct the window’s opening.

2. Determine the sash size of your window and its style — casement, awning, hopper. Our window is a hopper which swings open at the top.

3. Cut the fir into four pieces creating the frame (sash) of your window. Cut a rabbet edge in all four pieces to hold the glass.

HDSWT507_Windows_assembli_s4x3

HDSWT507_Windows_assembli_s4x3

4. Use the stile-and-rail bits to cut the interlocking tongue and groove that will hold your frame together. Glue and clamp the four pieces together and allow the glue to set completely.

5. Place the window glass inside the frame. Secure the glass in place by inserting the push points. Put the spikes of the point into the wood just above the glass then use a putty knife to push the points into the wood.

HDSWT507_Windows_installi_s4x3

HDSWT507_Windows_installi_s4x3

6. Apply a bead of glazing compound along the seam where the wood and glass meet. Take the putty knife and run it across the glazing at a slight angle to smooth it out. This will seal the glass to the frame and make it weather-proof. When the glazing compound is dry, install wood trim over the seam.

7. Install one side of the piano hinge onto the bottom of the window frame and screw the other side of the hinge onto the window sill.

HDSWT507_Window_install_s4x3

HDSWT507_Window_install_s4x3

8. Fasten the sill to the window opening. Attach wooden trim pieces around the the frame to hold it in place and to help seal the it. Attach chains between each side of the window frame and the window casing (these hold the hopper-style window open). Finally, attach the latch.

Keep Reading

Next Up

How to Install Windows

Let there be light and ventilation with these step-by-step instructions.

Custom Upper Cabinets

Lacking storage space? Add some vertical storage or display space to a room by building custom upper cabinets.

Building a Birch Kitchen Island

John and Jimmy DiResta build a custom kitchen island with a birch countertop and a slide-out butcher block. They add a custom base with storage bins, a recessed bowl and a steel pot rack.

Expanding a Window to a Door

Add an extra opening to your home by converting a window to a door.

Make a Window Seat With an Integrated Pet Bed

Turn unused space into a window seat with a cozy pet bed tucked in below.

Building a Customized Kitchen Island

Every kitchen can use some more counter space. Adding an island can help solve that problem.

A Blooming Good Gift Topper

A ribbon rose and pearl topper will give a gift an elegant flourish.

How to Build an Ironing-Board Cabinet

Follow these instructions for constructing a laundry-room space-saver.

$100 Half-Day Designs: Hanging Room Divider

Separate a room with a colorful window room divider.

How to Install Gutters

Protect against water damage to your foundation, basement and driveway with these instructions.

On TV

House Hunters

8:30am | 7:30c

House Hunters

9:30am | 8:30c

House Hunters

10am | 9c

House Hunters

10:30am | 9:30c

House Hunters

11am | 10c

Best House on the Block

11:30am | 10:30c

Fixer Upper

12pm | 11c

Fixer Upper

1pm | 12c

Fixer Upper

2pm | 1c

Fixer Upper

3pm | 2c

Fixer Upper

4pm | 3c

Fixer Upper

5pm | 4c

Fixer Upper

6pm | 5c

Fixer Upper

7pm | 6c
On Tonight
On Tonight

Fixer Upper

8pm | 7c

House Hunters

9:30pm | 8:30c

House Hunters

10pm | 9c

Fixer Upper

11pm | 10c

House Hunters

12am | 11c

House Hunters

12:30am | 11:30c

House Hunters

1am | 12c

Fixer Upper

2am | 1c

Fixer Upper

3am | 2c

Follow Us Everywhere

Join the party! Don't miss HGTV in your favorite social media feeds.