Making New Window Screen Frames For Your Camper

how to make new window screen frames for camper

Creating new window screen frames for a camper can be a challenging yet rewarding endeavour. It is a great way to give your camper a personalised touch while also improving its functionality. Whether you're an experienced DIY enthusiast or a beginner, making new window screen frames is a project that can enhance your camper's aesthetics and comfort. In this article, we will explore the steps involved in crafting custom window screen frames, from designing and building to installation and maintenance. We will also discuss the tools and materials required, as well as provide helpful tips and tricks for a seamless and professional finish. So, get ready to roll up your sleeves and embark on the journey of transforming your camper's windows!

Characteristics Values
Difficulty Challenging
Tools Required Flathead screwdriver, putty knife, razor knife, spline roller
Materials New roll of window screen, PVC spline, wood
Techniques Remove old screen, install new screen, cut and smooth screen, attach screen to frame

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Removing the old screen

Step 1: Remove the Screen and Frame

If you are replacing multiple screens, it is advisable to remove the entire frame with the damaged screen as one piece. Gently lift the screen frame from the bottom using a putty knife, and it should come out of the window frame. Place the frame on a flat surface with enough room to work on it. This step is especially useful when dealing with multiple replacements, as it allows for easy reinstallation later.

Step 2: Prepare for the Removal

If your frame is stuck and difficult to remove, utilise a putty knife to pry it out gently. You may need to apply some leverage to pop the frame out of the window gently. Once the frame is out, lay it flat on a table or workbench.

Step 3: Remove the Existing Spline

Use a flathead screwdriver to remove the PVC spline, which is a thin, rubbery, gasket-like material that holds the screen in the frame. Insert the screwdriver into the groove of the frame and carefully scrape out the existing spline. This step is crucial to releasing the screen from the frame.

Step 4: Take Out the Screen

After removing the spline, the screen should come out easily. Pull the screen out of the frame, and you will notice that it offers little to no resistance. Now that the screen is out, you can discard it, along with the old spline, or keep them aside for measurement reference for your new screen installation.

Step 5: Clean the Frame

Before installing the new screen, it is essential to clean the frame thoroughly. Use a microfiber cloth, or if needed, soap and water, to remove any dirt, dust, or debris from the frame. This step ensures that your new screen will fit properly and creates a clean surface for the new spline to adhere to.

By following these steps, you will effectively remove the old screen from your camper window, paving the way for a smooth installation of the new screen. Remember to work carefully and take your time to avoid damaging the frame or any other components.

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Choosing the right screen material

Durability and Strength:

Metal screens, typically made from aluminum, are known for their strength and durability. They are ideal for areas with tough insects and provide a clear view. Metal screens are robust but less flexible, making them prone to permanent dents from impacts. They also have limited width options, which can restrict their use in larger spaces.

Flexibility and Ease of Installation:

Fiberglass screens are flexible and can withstand everyday wear and tear. They are lightweight, corrosion-resistant, and suitable for coastal climates. Fiberglass screens are easier to install than metal screens and can be sized for various projects. However, they have limited colour options and may be more susceptible to certain insect damage.

Robustness and Versatility:

Polyester screens are strong, durable, and weather-resistant, making them suitable for various outdoor applications. The construction of polyester screens involves coating yarn with vinyl through an extrusion process, resulting in larger and more durable yarns. Polyester screens are ideal for sun shading and protection against smaller insects.

Insect Protection:

For effective insect protection, finer mesh materials are recommended. Polyester screens, such as TuffScreen® No-See-Um, or tightly woven fiberglass screens excel at keeping out even the smallest insects while maintaining good airflow.

Climate Considerations:

Consider the climate of your camping locations. If you frequent coastal areas, choose water and rust-resistant materials like fiberglass. In windy climates with flying debris, opt for more durable options like Tuff screens.

Visibility and Transparency:

If expansive views and outward visibility are important to you, select materials with high transparency. This will also benefit any indoor plants that require ample sunlight.

Privacy and Sunlight Control:

Densely woven screens can provide privacy and block heat. Solar screens, for example, have a dark exterior that absorbs excess heat and provides additional privacy while reducing natural light by 30-40%.

In summary, the best material for your camper window screens depends on your specific needs. Metal screens offer strength and durability, fiberglass provides flexibility and corrosion resistance, while polyester screens deliver robustness and versatility. Consider the climate, your need for visibility, privacy, and insect protection, and choose the screen material that best suits your camping environment and preferences.

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Installing the new screen

Now that you have your new window screen and frame, it's time to install them. Here is a step-by-step guide to help you through the process:

Step 1: Prepare the New Screen

Take your new screen and unroll it over the frame. Position it so that there is at least a half-inch of overhang on each side of the frame. Cut the screen with a razor knife, and make small 45-degree incisions at each corner to ensure a neat insertion.

Step 2: Insert the PVC Spline

With your spline roller handy, align the PVC spline with the groove of the frame at one of the corners. Push the spline into the groove using the roller, keeping the screen taut with your other hand.

Step 3: Roll the Screen

Continue rolling the spline tool down the length of the groove, keeping the screen tight. When you reach the end of the side, cut the spline with the razor knife and repeat the process for the remaining three sides. The screen will become tighter as you move along.

Step 4: Trim Excess Screen

Once you've rolled the screen into all four sides, trim away any excess screen material with your razor knife. Ensure that the screen is evenly smoothed out on the frame.

Step 5: Reinstall the Frame

Now, your new screen window is ready to be reinstalled. Pop it back into place in the window. You can use a putty knife to help you get leverage if needed.

And there you have it! You can now enjoy fresh air in your camper while keeping those unwanted bugs and insects at bay.

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Measuring and cutting the frame

Taking Measurements:

  • Measure from side to side: Place your measuring tape between the exterior window trim at the top and bottom of the window. Note the smallest dimension you get.
  • Measure from top to bottom: Measure the distance between the exterior trim and the window sill on both the left and right sides of the window. Again, make sure to note the smallest dimension.
  • Adjustments: It is recommended to subtract 1/4" from each of the smallest dimensions you obtained. This adjustment accounts for about 1/8" of movement due to seasonal changes, ensuring your window screen frame fits snugly all year round.

Cutting the Frame Pieces:

  • Using the adjusted measurements, determine the length of each piece needed for your window screen frame. Typically, you'll need stiles and rails for the sides and top of the frame, as well as a bottom rail.
  • Cut the pieces accordingly from your chosen wood. For a standard window, you might cut 2 stiles from a 1x3 to 48", 2 rails from a 1x3 to 22 3/4", and a bottom rail from a 1x4 to 22 3/4".

Biscuit Joints and Assembly:

  • To ensure a strong joint, you can cut biscuit joints into your frame pieces. Use a biscuit joiner or a similar tool to cut slots for biscuits (#10 or #20 depending on the joint size). Test fit the biscuits, apply wood glue, and then insert the biscuits into the slots to join the pieces.
  • Clamp the assembled frame and double-check that it is square by measuring from corner to corner. Ensure everything is aligned correctly before proceeding.

Creating the Groove for the Spline:

  • Measure about 3/8" from the inside edge of the frame and then mark an additional 1/8" from that point. The groove for the window screen spline will be cut between these two marks.
  • Using a router with an appropriate bit (e.g., 1/8" straight router bit), cut the groove for the spline along the sides and top of the frame first. Start at one corner, plunge the router into the layout line, and work towards the opposite corner.
  • Adjust the router fence as needed for the bottom rail, and then cut the groove for that side as well.

Now that your frame is measured and cut, you can proceed to the next steps, such as painting or staining the frame, installing the screen, and final installation back into your camper window.

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Attaching the screen to the frame

Preparing the Screen and the Frame

Before you begin, ensure you have a new roll of window screen, a flathead screwdriver, and new PVC spline—a thin, rubbery, gasket-like material that securely holds the screen in the frame. Lay the frame on a flat surface, and if necessary, use a putty knife to gently lift and remove the old screen.

Positioning the New Screen

Take your new screen and carefully unroll it over the frame. Position the screen so that it overhangs the frame by approximately half an inch on each side. Use a razor knife to cut the screen, making small 45-degree incisions at each corner to ensure a neat fit.

Securing the Screen with PVC Spline

With your spline roller ready, start at one corner of the frame. Align the PVC spline with the frame groove and use the spline roller to push it in, securing the screen in place. Keep the screen taut with your free hand as you roll the spline tool down the length of the groove. When you reach the end of the side, cut the spline with the razor knife.

Trimming and Finishing

Repeat the process for the remaining three sides of the frame. As you work your way around, you will notice the screen becoming tighter and tighter. Once you have completed all four sides, carefully trim away any excess screen material with your razor knife, ensuring a smooth and tidy finish.

Your newly screened frame is now ready to be reinstalled in your camper window. Use a putty knife to gently lift and position the frame back into place. Now you can enjoy fresh air in your camper while keeping those pesky bugs out!

Frequently asked questions

First, measure the window frame you'll be putting the screen in. Purchase a window screen kit with enough material for your window's measurements. Cut the provided aluminum pieces to size and assemble them with corner inserts. Cut some screening material so it's 1 inch bigger than the frame. Finally, use a spline roller to press the screen and some rubber spline into the back of the frame.

You will need a hacksaw, a metal file, a spline roller, and a utility knife.

You will need a window screen kit, which includes aluminum frame pieces, corner inserts, and a rubber spline. You will also need screening material and a flathead screwdriver.

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