Building your own windows and resources

[BigAl]

Hi Guys and Gals, I have decided to build my own windows. I could have bought them ready made, but I *want* to build them.

I have four sheets of 1/8"(3mm) Lexan, polycarbonate. The Lexan sheets measure 16 1/2"(420mm) x 11 2/3"(297mm).

My door is 1 1/3"(34mm) wide.

I would like to build a double glazed window for each door. Double glazed as I intend to use my trailer all year. I would prefer that the window could open for ventilation, but this is not essential as I could add ventilation slots to the doors.

Does anybody have any solutions to the design challenges I will face, or links to diagrams or plans? I have done a few searches for windows in the forum, but so far I haven't come up with anything detailed enough to help me build the windows.

For those of you who have have a preference, would you recommend opening windows or ventilation slots in the doors? I already have a 1' x 1' ceiling vent.

[claw73]

I will be eyeing this pretty intently. I can't help you with the design of the windows because I haven't heard anything either. I too will have left over lexan and would like to build windows that open.

GOOD LUCK!

[Ageless]

Unless you have some really wazzoo equiptmment, you might rethink double pane. You have to get a perfect seal then evacuate the air with an inert gas. This is to prevent condensation between the panes. A better solution would be a storm window where one pane is removable to allow occasional cleaning.

[BigAl]

Thanks Ageless, Your recommendation will definately make it into my final design. :)

[bobhenry]

So your window will be approx 18" wide by 24" tall ?

Look at some 60 - 80 year old homes with wooden double hung windows.

I think you could miniturize these and have a real cute double hung setup.

An exterior mounted full size storm for you winter mode and the same frame with a full screen for summer. I have double hung aluminun sash type windows and each sash is easily removable to mount a small window shaker air conditioner if I wish.

[angib]

You have to get a perfect seal then evacuate the air with an inert gas. This is to prevent condensation between the panes.

Good point, though some silica gel crystals in the gap might achieve the same result - though hiding them from sight might be hard. Making one pane removable (with some work) might be a sensible precaution.

It's worth mentioning that the double glazed effect works nearly as well with a tiny gap - early UK D/G units had a 4mm spacer so there's no need to go wild making a massively thick window.

How about a trip to your local double glazing company to find out where they get their sealed units made? If you don't want a guarantee, I think you might find that they could assemble your Lexan into sealed units (ie, just the polycarb and the spacer) and avoid the condensation issue. Then you just need a light wood frame to sit them in.

Andrew

[dh]

Hi Guys and Gals, I have decided to build my own windows. I could have bought them ready made, but I *want* to build them.

I have four sheets of 1/8"(3mm) Lexan, polycarbonate. The Lexan sheets measure 16 1/2"(420mm) x 11 2/3"(297mm).

My door is 1 1/3"(34mm) wide.

I would like to build a double glazed window for each door. Double glazed as I intend to use my trailer all year. I would prefer that the window could open for ventilation, but this is not essential as I could add ventilation slots to the doors.

Does anybody have any solutions to the design challenges I will face, or links to diagrams or plans? I have done a few searches for windows in the forum, but so far I haven't come up with anything detailed enough to help me build the windows.

For those of you who have have a preference, would you recommend opening windows or ventilation slots in the doors? I already have a 1' x 1' ceiling vent.

Do you want to build them, or do you want to save some money? If you want to save some money, look into used windows at some of the larger camper dealers.

[dwgriff1]

There are many ways to "build" windows.

Andrew had a tutorial on a hopper window used on boats in his country.

It requires some careful wood joinery and Plexiglas. I used his design in my build. It worked well. Right now I am refurbishing the trailer and changing some design ideas, including the windows. They will still be hopper style though.

I like these windows because I can take the whole glazing out and have maximum ventilation. If it gets cooler in the night (it does that around here) I can quickly put the glazing back in place.

dave

[BigAl]

Hi Dave, If I recall correctly the pane is loose and wedged closed from the top? Do you have a link to the thread?

[dwgriff1]

I emailed Andrew and he sent me a PDF file.

How do I send that file to you?

Maybe Andrew will chime in here. He is a bundle of good information.

dave[/img]

[claw73]

I found someone that is making round windows that have two panes where each pane is cut oppositely. Then you twist one pane making the holes line up and creating an open window. It was mentioned on an ehow article I can't find right now, but think of a spice top that is twist to open. I'm going to figure out how to build mine today and then I'll let you know.

[Conestoga]

I found someone that is making round windows that have two panes where each pane is cut oppositely. Then you twist one pane making the holes line up and creating an open window. It was mentioned on an ehow article I can't find right now, but think of a spice top that is twist to open. I'm going to figure out how to build mine today and then I'll let you know.

sounds interesting. i'd like to see it.
i googled but didn't find anything yet.

here's a simple solution for a second "pane" made of reflectix.
bubblewrap without the foil would let light in.

from the album of Mike

[dwgriff1]

My rebuilt windows do not include a screen (I will attach that to the outside via small magnets when I camp). Permenent screens left too much space between the glazing and the edge of the tear, place for water to accumulate.

I made moldings that would hold the same weather stripping used in the new house doors I see around here. The Plexiglas will be glued via silicone to a finger joint frame -- no metal fasteners to rust.

Plexiglas and silicone do not make a perfect bond, my glass man tells me. I'll sand the edge of the Plexiglas a bit and then be ready to redo the silicone it every few years if it is necessary.

The wood frame behind the Plexiglas will have a piece of the same weather stripping as the sides of the frame. The whole unit will push tight against the sill, which has a dam on the inside and is set at a fair angle for better run off.

Up here we often need a LOT of ventilation in the early evening and very little later. That is what I like about this system where you can lift out the entire glazing and all of the window becomes ventilation.

Andrew's design did not include screens, and the way I solved it seemed good at the time, but I think the new system will work better.

I do not have curtains inside the tear. The screen pretty well blocked day time vision into the trailer. This time I am using bronze colored Plexiglas.

dave

[BigAl]

Hi Guys, Thanks for that great information already I am thinking about issues I might otherwise not thought about without your help.

I would love to see those circular windows. I'm guessing they look somethink like this only made from plexiglass?

Oh damn, I have already started my windows by bonding the Lexan to Oak frame using... silicone. I built a double glazed unit where one of the panes can be unscrewed to enable cleaning and lessen the trapped moisture issue. Kind of like a semi-permanent storm window as suggested by Ageless. I will post a photo when I find my camera.

So far I have just built the gazing unit I don't have a window frame as yet.

[BigAl]

Here is a photo of the two double glazed units I have built. My mitres are terrible. eek!


I ripped down some white oak to 1x1/2" to make the frames and cut out a rebate to receive the Lexan with my table saw.

I made four single glazed units and screwed two of the units together to make double glazed units.