03/11/2026
Making your own window screens is some work but fun and pretty easy. I did get a blister on my right hand from using the spline roller but it was worth it!
Materials you need:
Screen (appropriate size of course)
Spline by the foot ( make sure you have enough.
Spline roller
Aluminum stock for screens ( get 2 extra pieces and cut smart, to get maximum results)
Corners
Springs
Razor knife
Tape measure
Needle nose pliers
Hacksaw ( or sawsall or any saw really. Remember aluminum melts when hot and you will need a file or sandpaper to gently remove any extra.)
Measure the windows
Once measured deduct the corner(usually 3/4", so 1 1/2" for both corners) and then deduct 1/8" inch off of overall length. So, if your window length is 33 inches, deduct 1 1/2 for corners = 31 1/2" and then deduct 1/8" = 31 3/8". This gives you the proper measurement. Do this for the top, bottom, and both sides. It should be square on newer windows, but always measure at the top and the bottom.
Use hacksaw and sandpaper, being careful not to remove the paint. Use needlenose pliers to correct any bending. Aluminum bends easily.
Next assemble the frame using 1 spring on the side piece and then add all of your corners. Make sure your spline groove is along the inside. The flat side of the corner goes with the flat side of the aluminum stock, it literally will not fit any other way.
After this step I goto the inside of the window and test the screen to the window. Open the window completely. Slide the top of the screen into the frame where the screen will sit just outside the glass. (Older windows are done differently but I am sure yours will be newer. ) You may need to pull the screen down to fit into the groove and make sure it reaches the frame all the way around.
Next remove the frame and place face down on a tarp or cardboard so you don't scrape the aluminum. Roll screen over frame making sure you have about 2 inch overhang. Try and keep the lines in the screen lined up the frame. It will work best keeping it squared up.
Next measure your spline for the full window and cut it from the roll. Then start your spline in a corner by pushing it into the opening with your roller.
Spline has come a long ways in 30 years and is much easier to work with these days but it can still be a handful. Your spline roller has two rollers. One is a single flat side and the other has a double bump in it. I like to use the double. Be very careful to keep your roller closest to the outside edge.
Go slowly, it is best to take your time because if you slip and your roller goes through the screen and you have to pull up the spline and realign or replace the screen.
Make sure and keep your screen squared and tight all the way around. Once finished if you notice any bowed out ( bubbled) screen just pull the spline from the closest corner and tighten, then reroll spline. I will cut the spline in the corner and pull it back then replace spline with spline roller tightening the screen, cut excess spline with razor in corner.
Once you have a nice flat screen then you can carefully trim the excess screen. You want to avoid touching the inside of the screen with the razor or spline roller as it will damage the screen and you will have to start again.
Place screen from inside house with the spline in.
Please feel free to reach out with any questions.
