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How to Build Plexiglass Storm Windows

Plexiglass is a long-lasting and low-cost material for storm windows. The material is as clear as glass, easy to work with, and weather resistant. Learn how to build your own storm windows to reduce the impact of cold weather on your home. The project is suitable for someone who is familiar with using a table saw. If you have a lot of windows to do, the project will take a long time.

How to Build Custom Storm Windows

  1. Take measurements of the window’s height and width from the exterior.
  2. Increase the dimensions by 2 inches to determine the height and width required for the storm window.
  3. Cut a piece of plexiglass to fit these dimensions. Your local hardware store might offer plexiglass cutting services, or you can purchase a sheet and cut it at home using a table saw. Remember to wear safety glasses when operating the table saw.
  4. Once the plexiglass is cut, equip the table saw with a dado blade, which cuts a wide groove to accommodate the edges of the plexiglass.
  5. Adjust the dado blade so that its highest point is 3/8 of an inch.
  6. Set the table saw’s fence to be 7/8 of an inch to the left of the blade.
  7. Place your 1-1/2 by 2 lumber on its edge.
  8. Gradually feed the lumber into the blade to create the groove.
  9. To construct your own storm windows, you will need to cut 45-degree angles on the ends of each frame piece.
  10. Replace the dado blade with a cross-cut blade.
  11. Set the table saw’s blade to a 45-degree angle.
  12. Attach a miter gauge to the table saw.
  13. Work with the lumber lying flat and make 45-degree cuts based on the required dimensions for the window frame.
  14. When assembling the frames, begin by applying a bead of silicone caulk inside the groove of one piece of lumber.
  15. Slide one edge of the plexiglass into the caulk-filled groove.
  16. Apply wood glue to the mitered end of the wood.
  17. Add caulk to the groove on the next piece of wood.
  18. Slide the groove of the second piece of wood over the plexiglass.
  19. Press its mitered edge firmly against the end of the first piece of wood.
  20. Repeat this process with the third and fourth pieces of the wood frame, caulking the grooves and gluing the corners, ensuring a tight fit.
  21. Secure your new storm window using a nylon strap clamp.
  22. Tighten the clamp until glue oozes out at the corners.
  23. Remove excess glue and allow the frame to dry.
  24. Secure each corner of the frame with two pin nails on both sides.
  25. Finish by painting the frame with exterior paint.

Tools & Materials

  • Measuring tape
  • Safety glasses
  • Table saw
  • Cross-cut blade
  • Miter gauge
  • 1/4-inch plexiglass
  • 1-1/2 by 2-inch poplar, cedar, or redwood lumber
  • Silicone caulk
  • Wood glue
  • Nylon strap clamps
  • Pin nailer
  • 1-1/4-inch pin nails
  • Paint roller and pan
  • Exterior paint

Storm Window Installation Experts

The window professionals at PJ Fitzpatrick possess extensive expertise in home exterior remodeling. Opting for new, pre-made storm windows for your windows ensures optimal outcomes. Save yourself the trouble of building your own plexiglass storm windows and reach out to us. Contact us today to inquire about a window installation estimate.

Need help with this project?

We have trained professionals that can help. Contact us today. 1-877-246-4354

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