build exterior solar shade screens

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initial requirements:

  • Unshaded windows facing east, southeast, south, southwest, or west

materials needed:

SHADE SCREEN ON WOOD FRAME:

  • Solar shade screen –– rated to block 60 to 80 percent of sunlight and sized at least 1 to 2 inches larger than the screen frame
  • Heavy-duty 1/4-inch staples for staple gun to attach the screen to frame
  • 3/4-inch or 1-inch brads to attach the screen molding to frame
  • Corrugated metal fasteners –– to hold together new frame
  • 1” x 2” lumber long enough for the frame
  • Construction adhesive or glue
  • Screen molding (if needed) to extend all around the frame
  • Exterior wood primer
  • Exterior paint to match window trim
  • Hardware to attach the screen over the window

SHADE SCREEN ON METAL FRAME:

  • Solar shade screen ––rated to block 60 to 80 percent of sunlight and sized at least 1 to 2 inches larger than screen frame
  • Rubber spline to hold the screen in the metal frame
  • Hardware to attach over the window

tools needed:

Shade screen on wood frame:

  • Pry bar (for installing on old frame)
  • Mitre box with backsaw (if installing on new frame or replacing screen molding on old frame)
  • Paint scraper or steel wire brush (for installing on old frame)
  • Heavy-duty stapler
  • Carpenter’s tool belt (see Rules for Tools section in Chapter 3 of the Home Energy Projects Manual)

Shade screen on metal frame:

  • Screen spline roller
  • Scissors
  • Carpenter’s tool belt (see Rules for Tools section in Chapter 3 of Home Energy Projects Manual)
  • Electric drill and drill bits (if installing on new frame)
  • Mitre box and backsaw (if installing on new frame)

required skills: Basic carpentry

annual energy savings: $.27 to $.44/sq ft

average time required: ¼ to 1 hour to fabricate and install each screen

project steps:

REPLACING AN INSECT SCREEN ON A WOOD FRAME WITH A SOLAR SHADE SCREEN

  1. Remove the screen molding from the old screen. Be careful if you want to reuse the molding –– it breaks easily.
  2. Remove old brads and staples with a screwdriver, hammer and pry bar.
  3. Clean flaking paint on the frame with a paint scraper or steel wire brush.
  4. Cut the shade screen 1/4 inch larger than the outside dimensions of the old screen and lay it in place on the wooden frame.
  5. Staple the solar shade screen to the top of the frame –– be careful to keep the screen’s thick weave straight across the frame. Then, stretch the screen evenly toward the bottom and staple.
  6. Staple one side down; then, stretch the other side and staple it down.
  7. Trim the excess screen with a utility knife.
  8. If you are reusing old screen molding, tack it in place with 3/4- inch or 1-inch brads.
  9. If you are replacing the screen molding, use a mitre box to cut molding with 45-degree corners.
  10. Mount the screen in the window.
  11. Make sure you remove the shade screen in winter.

INSTALLING A SHADE SCREEN ON A NEW WOOD FRAME

  1. Measure the outside frame of the window. Be accurate –– the frames of older windows may have shifted and the corners will no longer be at right angles.
  2. Using a mitre box, cut pieces for the window frame out of 1” x 2” lumber at a 45-degree angle. Lay the pieces on a flat surface to check the dimensions and ensure the mitred edges fit tightly.
  3. Glue the frame together and use the corrugated fasteners to assemble it. Drive two 1-1/2-inch brads through the edge into each corner joint to ensure a solid connection.
  4. Follow steps 4 through 10 in the previous section (replacing an insect screen on a wood frame with a shade screen).
  5. Make sure you remove the shade screen in winter.

REPLACING AN INSECT SCREEN ON A METAL FRAME WITH A SOLAR SHADE SCREEN

  1. Remove the old screen from the metal frame by gently pulling out the rubber or plastic spline –– be careful if you plan to reuse the spline.
  2. Cut a piece of the shade screen 1 to 2 inches larger than the outside dimensions of the old screen.
  3. Place the shade screen over the frame. Starting at the top left-hand corner, lay the rubber spline on top of the screen directly over the groove in the frame.
  4. Roll the spline roller in a clockwise direction to press the spline and the screen firmly into the groove. Continue around the frame until you reach the starting point. As you proceed, keep the weave even in the frame.
  5. Trim any excess screen from the spline using the utility knife.
  6. Install the shade screen frame in the window.
  7. Make sure you remove the shade screen in winter.

INSTALLING A SHADE SCREEN ON A NEW METAL FRAME

  1. Measure the outside frame of the window.
  2. Cut four pieces of aluminum frame stock to form the top, bottom, and sides of the frame. For larger screens, you may also need a center support bar and clips for attaching it to the frame.
  3. Slide the frame pieces onto the metal corner brackets. Set the completed frame into the window to check the fit. Make any needed adjustments.
  4. Follow steps 2 through 6 for the previous procedure in this section (replacing an insect screen on a metal frame with a solar shade screen).
  5. Make sure you remove the shade screen in winter.