How to Make a Wood Screen Window Frame With a Kerf Saw

Wood screen windows are beautiful additions to any home or screen porch area. While many tools can be used to make a screen window, a common tool in many sheds is a hand kerf saw. This saw can be used to make all the cuts and have your window made in a short period.

Things You'll Need

• Kerf Saw
• Measuring Tape
• Pencil
• Wood Glue
• Screen netting
• Staple Gun
• Nail Gun
• Clamps
• Chisel
• Sandpaper
• 8 wood slats 2-by-1-by-36

Instructions

1. Measure the location the window will be located. Mark each wood slat to the appropriate length based on the window size needed. Four pieces will be for the top and bottoms and the other four will be for the two sides.

2. Mark each wood slat at the ends with a 45-degree line with the pencil, having the longest part of wood slat match the measurement needed for the outside window piece.

3. Clamp the wood slat down to a stable surface, with the end that will be cut exposed and not in the way of any other furniture or surfaces. Line up the kerf saw with the 45-degree angle mark and cut away any excess. Do this for each end.

4. Take two pieces, one top and bottom, and the other two pieces, two sides, and lay them to form the first side of the frame. Match up the 45-degree cuts and inspect for any gaps. Use a chisel or sand paper if needed to even the edges and have them match.

5. Apply wood glue to each corner at the 45-degree cuts and line the frame up. Use the clamps to secure the frame together. Use the nail gun to drive a nail through each corner. Set to the side for two hours to allow the glue to dry and set. Repeat for the second frame.

6. Lay the screen roll across the first frame and cut to the outer edge of the frame. Use the staple gun to secure the screen to the frame, starting at the top of the frame.

7. Work your way down the frame pulling the screen tight and stapling to the frame, switching from side to side. End by pulling the screen tight at the bottom and staple into place. Cut off excess screen that extends past the frame edge.

8. Apply a generous amount of wood glue over the screen that was attached to the frame area. Line up the second frame on top of the first, covering the stapled screen area.

9. Clamp the frame together and use the nail gun every two inches to secure the two frames together. Allow the glue to set for two hours.

10. Place the new wood screen window into the location it is needed and use the nail gun to secure it into place.

Tips & Warnings

• The frame can be stained with wood stain or clear coat seal if wanted to protect it from the weather.

• Safety glasses should be worn when making cuts with the kerf saw.

References

• Walter Carter, Carpenter, West Point, VA