How to Build a Metal Screen

Measure the corner-to-corner dimensions of the inside of an open window frame. Add 1/16 inch to those measurements to determine how much screen material to purchase for the new window screen. Subtract 4-5 mm from those measurements to determine the size of aluminum that you will need to fit inside the window frame itself if you do not have the old original metal screen from the window to use as a guide.

Cut the end corners of the aluminum frame pieces at a 45 degree angle, using the miter to measure the angle and the hack saw to cut the aluminum pieces.

Insert the window screen braces into each end of the aluminum pieces. Connect the window screen pieces to one another so that the metal frame of the screen is square.

Lay the metal window screen frame on a flat surface. Be careful not to bend or warp the frame.

Lay the screen material out over the top of the aluminum screen frame. Trim the window screen with the scissors so that you leave about 1 inch of screen material overlapping the aluminum screen frame on all four sides.

Insert the rubber (or metal) window screen spline into the aluminum screen frame channels over the top of the screen material using the convex end of the spline roller tool. Try to keep the top part of the mesh screen at an even length without letting it ripple up all of the way across one edge of the aluminum screen.

Gently pull the screen material across the opposite end of the aluminum metal frame. Insert the window screen spline into the screen frame channels using the spline roller tool again. Repeat the same process on both sides of the window screen frame. Trim off any excess screen with a scissors. Keep the spline part of the screen facing inward when installing the screen into the window frame slots.