Pocket Replacement Window Installation Instructions Pocket Replacement Window Installation Instructions Go From: • Drafty • Energy Wasting • Hard Operating • High Maintenance Windows To: • New • Energy Saving • Easy Operating • Low Maintenance Windows In a few easy steps.
Table of Contents and Tool/Material Requirements Double Hung Wood Window Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Project Scope; Measuring for a Perfect Fit; Why a Pocket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Window Measuring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Double Hung Wood Window Components Sheathing Header Drywall Interior Top Casing Head Inside Stop Head Outside Stop Head Brickmould Top Sash The instructions that follow are based on removing a typical double-hung wood window from standard wood frame construction. Insulating Glass With Grids The scope of these instructions does not permit covering every type of window and all possible installation varieties.
Project Scope This window modernization method uses the existing window frame, sill, and the interior trim. The new unit is sized to fit into the existing window frame and butt against the outside stops. After removing the old window sash and some stops the opening is repaired as needed, the new window installed, insulation added, and lastly trim is applied as needed.
Window Measuring Instructions MEASURING YOUR WINDOWS (For All Exterior Trim Types) Step 1. From the interior. Measure the Interior Width Jamb to Jamb (D) and Interior Height Sill at Stool to Head Jamb (E) as shown in Figures 1 & 2 below. Record these measurements on the following window order form. Special shape windows are also available. Measure width (D) in both upper and lower sash areas and at three places along the height. Record the smallest width.
Remodeling & Replacement Series Window Order Form NOTE: When ordering units with differing specifications, please use a separate form for each unit.
Remove Old Window Interior Components – Wood Frame Building FIGURE 1 SIDING DRYWALL Improper use of hand and power tools could result in personal injury and/or product damage. Follow equipment manufacturers’ instructions for safe operation. Always wear safety glasses. RO FRAMING BRICKMOULD HEAD JAMB TOP SASH INTERIOR TOP CASING IMPORTANT: Wear protective clothing including safety glasses, gloves, long sleeved shirt, long pants, sturdy footwear, and hearing protection.
Remove Old Window Interior Components – Wood Frame Building (cont.) Remove Bottom Sash (cont.) FIGURE 5 Move sash slowly and carefully to prevent glass from shattering. Wear full protective clothing including gloves and safety glasses. Pocket Replacement Window Installation Instructions INTERIOR FIGURE 6 CUT SASH CORD NOTE: Unlock any sash or tilt locks. If present, hold spring-loaded side bolts in the disengaged position. 3. Lower bottom sash so it rests just above the stool. 4.
Remove Old Window Interior Components – Wood Frame Building (cont.) Remove Top Sash FIGURE 8 NOTE: If top sash is stationary, remove the support blocks at the bottom of the top sash (FIGURE 8). Be sure to hang on to the sash so it will not fall when its support blocks are removed. If sash is “painted-in”, insert a putty knife between sash and side and head parting stops. Work knife around all sides to break paint seal. 2.
Remove Old Window Interior Components – Wood Frame Building (cont.) 1. With sash removed, inspect window frame for damage, rot, warp, twist etc. Fix any problems before continuing. FIGURE 1 2. Remove and discard sash weight pulleys from both sides (FIGURE 1). Fill pulley holes with fiberglass insulation (FIGURE 2). Pocket Replacement Window Installation Instructions 3. Open sash weight pocket in side frames (FIGURE 3), remove weights and rope (FIGURE 4). Fill pockets with fiberglass insulation.
Remove Old Window Interior Components – Wood Frame Building (cont.) FIGURE 5 4. If windows are mulled or adjacent, check mull posts to see if they have hollow cavities. Fill with fiberglass insulation and then reclose (FIGURE 5). 5. For trim that was removed and will be reused, pull old nails through from the back to prevent damaging the exposed face of the trim (FIGURE 6). NOTE: If your replacement window units are ordered with exterior trim be sure to remove old exterior trim before continuing.
Remove Old Window Exterior Components – Wood Frame Building (cont.) FIGURE 1 IMPORTANT: If you will not be replacing your exterior trim, skip to the next page. Removing Old Exterior Trim If you are replacing your old trim proceed as follows. Pocket Replacement Window Installation Instructions 1. Use a sharp utility knife and cut through caulk that surrounds the head and sides of the old trim (FIGURES 1 & 2). Cutting through the caulk reduces the possibility of siding damage as the trim is removed. 2.
Opening Preparation – Wood Frame Building FIGURE 1 IMPORTANT: High-quality, exterior, neutralcure, clear, silicone sealant (compatible with window materials and exterior face of the wall) is to be used for all procedures in the following instructions which call for caulking or sealant. MEASURE OPENING HEIGHT 2 PLACES 1.
Opening Preparation (cont.) – Wood Frame Building 3. Examine the existing sill. If the sill nose needs to be replaced proceed as follows. (If sill is good, continue with Step 6 below). FIGURE 5 4. Draw a line across the sill that lines up with the outside face of the outside stops (FIGURE 5). 5. Cut off old sill along this line. Cut must be straight, even, and parallel to the siding in both vertical and horizontal planes.
Window Installation 1. From the interior, lift the window into the opening. Bottom inside edge rests tight against stool and sits on sill caulking. Outside edges of side frame and head must butt tightly against caulk bead applied to outside stops (FIGURES 1, 2 & 3). FIGURE 1 2. Center the unit from side to side in the opening. FIGURE 2 INTERIOR NEW WINDOW FITS TIGHT & FLUSH AGAINST THIS FACE. STOOL OUTSIDE STOP FIGURE 3 OUTSIDE STOPS 14 Pocket Replacement Window Installation Instructions 3.
Window Installation (cont.) 4. While holding unit in place, check unit for plumb and level on interior or exterior (FIGURE 4). FIGURE 4 Pocket Replacement Window Installation Instructions 5. Shim at head (FIGURE 5) and side jambs (FIGURE 6) so unit is level and plumb. Place shims between side jambs and head and the old window frame. Locate shims at the pre-drilled fastening holes. Fasteners should penetrate the shims. 6. When unit is level and plumb, unlock and lower top sash.
Window Installation (cont.) FIGURE 8 EXTERIOR CAULK BEFORE INSTALL 8. Insulate gap between new window frame and old frame with fiberglass insulation. Do not over pack insulation. Run a bead of sealant along joints where new window and old window frames meet (FIGURE 8). 9. Use appropriate length finish nails and reinstall the head and side inside stops (FIGURES 9 & 10). NOTE: If the inside stops were damaged during removal, obtain and install new pieces (FIGURE 11).
Trim Window Exterior to Fit Siding Trim is used to close the gap between existing siding and the new window unit (FIGURES 1 & 2). FIGURE 1 Several trim pieces are available to help complete your installation. The pvc trim can be cut, ripped, routed, and fastened with standard woodworking tools and fasteners. It comes in three standard colors white, tan, and carmel green. It can also be painted to match our selection of available aluminum colors. For nailing, a pneumatic nail gun is recommended.
Trim Application Any trim application should be based on: FIGURE 1 • Gap size that needs to be bridged • Siding material • Matching other exterior features General guidelines and examples of using our “trimout” products follow. 2. Cut tape to the width of the gap. Sill and head pieces go full width. Side pieces go full height. Tape must be applied in proper sequence – sill piece first, side pieces next, and head piece last. 3.
Trim Application (cont.) 6. The pvc flat casing can be cut to length and ripped to fit gap as shown (FIGURE 5). Fasten to framing with rust-proof nails long enough to penetrate the framing by at least 1-1/2". FIGURE 5 FLAT CASING CAULK GAP 7. Caulk the gap between the trim and siding (FIGURES 6 & 7). Caulking provides additional weather seal and helps keep insects out.
Recommended Finishing Instructions Always follow chemical manufacturers’ safety instructions when using chemicals to avoid injury or illness. • Do NOT clean any surface with gasoline, diesel fuel, solvent based, or petroleum based products. • Do NOT use abrasive materials or strong acidic solutions against vinyl, aluminum, glass, steel, fiberglass, or factory-applied finishes. • Do NOT scrape or use tools that might damage the surface. • Do NOT paint vinyl or aluminum surfaces.
Pocket Replacement Window Installation Instructions Recommended Finishing Instructions (cont.) Window Sash PVC Trim All active and removable sash must be removed from the window frame after installation so they can be properly sealed (FIGURE 1). • Painting or finishing PVC trim is not required. Both clad and wood units have bare wood on the top and bottom of the sash. Paint or varnish these areas as you would all of the other exposed exterior wood.
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