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How to Build Your Own Storm Windows

Plexiglass offers a durable and affordable material for making storm windows. The material is as clear as glass, easy to work with, and resists harsh weather conditions. You can reduce the impact of cold weather on your home by learning how to build your own storm windows. The project is within the scope of a person comfortable working with a table saw. If you have many windows to do, the project will be time-consuming.

A Step By Step Guide On How to Build Your Own Storm Windows

  1. Measure the height and width of the window on the outside.
  2. Add 2 inches to the dimensions to get the height and width for the storm window.
  3. Cut a piece of plexiglass to fit these dimensions. Your local hardware store may cut the plexiglass to size. If you’re making multiple windows, buy a sheet and cut the pieces at home with a table saw. Wear safety glasses when using the table saw.
  4. After cutting plexiglass, put a dado blade into a table saw. A dado blade cuts a wide groove that you will fit the edges of the plexiglass into.
  5. Set the dado blade so that it is 3/8 of an inch high at blade’s highest point.
  6. Adjust the table saw’s fence so that it is 7/8 of an inch to the left of the blade.
  7. Position your 1-1/2 by 2 lumber on its edge.
  8. Slowly feed the lumber into the blade to cut groove.
  9. How to build your own storm windows requires cutting 45-degree angles on the ends of each frame piece.
  10. Replace the dado blade with a cross-cut blade.
  11. Adjust the table saw so that the blade sits at 45 degrees.
  12. Outfit the table saw with a miter gauge.
  13. Working with the lumber flat, make 45-degree cuts according to the dimensions needed for the window frame.
  14. To assemble frames, start with a bead of silicone caulk in the groove of one piece of lumber.
  15. Slide one edge of the plexiglass into the groove with caulk.
  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. Push its mitered edge tight against the end of the first piece of wood.
  20. Repeat this process with the third and fourth piece of the wood frame. Caulk the groove and glue the corners, pressing everything tightly together.
  21. Wrap your new storm window with a nylon strap clamp.
  22. Tighten the clamp so that glue oozes out at the corners.
  23. Wipe away excess glue and allow frame to dry.
  24. Secure each of the frame’s corners with two pin nails on both sides of the frame.
  25. Paint the frame with exterior paint.

Tools & Materials

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

New Storm Window Installation

The people at PJ Fitzpatrick are experts at home exterior remodeling. Outfitting your windows with new, factory-made storm windows will produce the best results. Spare yourself the hassle of how to build your own storm windows and talk to us. Ask us for a window installation estimate today.

Need help with this project?

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

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