How to Replace a Double Pane Aluminum Window

Double pane windows are another way of describing double hung windows,

which means both the upper and lower sashes will move up and down. If

the windows are made of aluminum rather than wood or vinyl, there's a

good chance that they are installed within a casing, so when it comes

time to replace them, you will need to cut the whole casing out of the

window opening. Once everything is out, reinstalling the new windows

is the same process, regardless of what style of window you choose,

because modern windows are all pre-hung within their casings.

Things You'll Need

• Tape measure
• Hammer
• Prybar
• Reciprocal saw with metal-cutting blade
• Double-pane aluminum or vinyl replacement window unit
• Shims
• Level
• Screwgun
• 3-inch galvanized screws
• Foam insulation
• Trim nailer
• Caulk

Instructions

1. Measure the width and height of the window opening from the inside of the tracks. Slide the sashes to get at the tracks, as needed. Order the new windows with the measurements. Leave the old windows in until they arrive.

2. Remove the trim from the perimeter of the existing window with your pry bar and hammer. Keep the trim intact as you remove it. Set it aside. Pull out the window sashes. If there is an aluminum casing attached to the window opening with screws or nails, run a reciprocal saw with metal-cutting blade between the casing and the wall frame to cut through the screws and extract the casing.

3. Set the window unit in the opening, bottom first. Ease the top back into the opening until it rests against the outer border of trim.

4. Push shims along the sides of the window unit while setting a level next to it, until it's level and square.

5. Shoot galvanized screws through the holes in the sides of the window unit, outward, into the wall frame.

6. Fill the spaces between the window unit and the wall with foam insulation, sealing the spaces completely.

7. Set the trim back around the window unit to cover the insulated space. Secure it with a trim nailer. Caulk around the window where it meets the trim.

References

• Family Handy Man: Window Replacement