How to Repair Broken Aluminum Window Pane

Most modern aluminum windows are designed to be easily removed to replace broken panes of glass. This involves removing the frame from the window and taking it apart to get to the broken pane. Replacement glass is available at most glass centers or home improvement stores in set sizes or specially cut to fit.

Things You'll Need

• Screwdriver
• Needle nose pliers
• New glass pane

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Instructions

1. Slide the retention panel away from the window by lifting up on the frame and pulling it from the bottom track. Some panels have screws at the top and bottom of the panel, so use a screwdriver to remove them and release the panel.

2. Carefully take the frame with the broken glass pane out of the window, by laying the frame on a flat surface and taking out the four set screws that hold the pieces together. Place the small screws in a safe place so that they won’t be lost.

3. Pull the frame apart to separate them from the glass pane. In some cases it is necessary to use a rubber mallet to tap the frame edges to loosen the glass. The surrounding glass may have a rubber gasket around it, so remove it for reuse if possible. Throw the old glass away.

4. Slip the rubber gasket around the edges of the new pane of glass. Be sure to get it over the glass completely, without twisting it so it lies evenly. If the gasket is too tight to pull over the glass by hand, use needle nose pliers to position it carefully.

5. Reassemble the aluminum frame over the glass and make sure the gasket fits securely inside the frame. Insert the screws into their holes and tighten them with a screwdriver. Press on the glass and wiggle the frame to make sure it’s tight.

6. Return the frame to the window opening and fit it back into place. Replace the screws into the outer track if necessary, and slide the retention panel back over the track to secure the new window pane again.

Tips & Warnings

• If the rubber gasket is cut, frayed or otherwise damaged, replace it with one of similar size and diameter.

• Use a tempered glass pane when replacing to add protection against further breakage.

• Use gloves when handling the bare glass in case there are sharp edges.

References

• “Black & Decker Complete Guide to Windows & Entryways;” Chris Marshall; 2008