How to Build a Custom Window Screen

When we purchased an old two-family home in desperate need of repair, our list of exterior projects were way too much to handle on our own. So we farmed out many of the big jobs—like siding and painting—to contractors, and kept some of the more manageable DIY tasks for ourselves.

One of the jobs we did ourselves was putting in custom window screens. Most of the screens that came with the house were torn and tattered, joined using metal corrugated fasteners that didn’t hold up well to the elements. I chose to rebuild them using 5/4-inch pre-primed finger-jointed stock that’s suitable for exterior use, and I’ll show you how to do the same.

Building custom window screens is particularly useful for older homes with non-standard window sizes or damaged screens. In this guide, I’ll walk you through the process I used to create durable, attractive window screens.

Building the Screen Frame

Creating a sturdy frame is the foundation of a quality window screen. This can be done using hand tools, though power tools are necessary to exactly follow the process described below.

Step 1. Cut and Prepare the Frame Pieces

Cut stiles and rails from 5/4” stock using a saw suitable for precision cuts. Rip pieces on a table saw to the desired width, ensuring the stiles and top rail are 2 inches wide while the bottom rail is 2¾ inches wide for additional support. Then sand the edges with 120-grit sandpaper for a smooth finish, ensuring no splinters or rough spots exist.

Step 2. Join the Frame

For a strong, long-lasting frame, I used floating tenons, which known for their strength and ease of assembly:

1. Mark locations for floating tenons on frame pieces.
2. Cut mortises using a Festool Domino system or similar tool, providing a precise fit for the tenons.
3. Dry-fit the frame to ensure proper alignment before gluing.
4. Glue and assemble the frame using 8mm x 50mm beech dominos

Step 3. Finish the Frame

Allow the glue to dry for about an hour, then sand the corners to remove any imperfections. Prime any exposed wood to protect it from moisture and other elements and apply two coats of exterior-grade trim paint.

Installing the Window Screen Mesh

A taut, properly installed screen mesh is crucial for function and appearance. I learned this technique from This Old House general contractor Tom Silva to achieve a perfectly taut screen with no sags or gaps.

Step 1. Prepare the Frame

Before attaching the screen, ensure the frame fits perfectly in the window opening and make the necessary adjustments:

1. Dry-fit the frame in the window opening to ensure proper size.
2. Trim the frame to fit if necessary, ensuring a snug fit.
3. Add a 7-degree bevel to the bottom of the frame to match the window sill pitch, allowing for proper drainage and fit.

Step 2. Attach the Screen

Set the frame on 1-inch high boards at each end to elevate it off the work surface. Then:

1. Clamp the frame in the middle to bow it. This will ensure the screen is taut when attached.
2. Staple the screen across the top and bottom rails.
3. Remove clamps and staple the sides, maintaining a tight fit.
4. Trim the excess screen with a sharp utility knife.

Step 3. Add Screen Molding

Cut screen molding using Wiss miter snips for clean, precise cuts. Here’s how to get it right:

1. Mark lengths with a utility knife to ensure accurate placement.
2. Attach molding with ¾-inch headless pins, securing it along the frame edges.
3. Use scrap pieces as a reference for consistent placement of the molding.

Final Touches and Window Screen Installation

Adding the final touches to your screen ensures it looks great and operates smoothly. Apply a final coat of paint to the entire assembly, sealing and protecting all surfaces. Install screen hardware, such as clips and handles, ensuring secure attachment to the window.

Finally, test the screen’s fit and function in the window opening, making any necessary adjustments to ensure smooth operation.

Seasonal Considerations

Screens are designed for warm-weather use. Proper seasonal maintenance will prolong their life and functionality. Store screens properly during colder months to protect them from harsh weather conditions, replacing them with storm windows to insulate and protect your home’s interior.