About 4 years ago I made new screens for my 25-year-old aluminum single-hung windows. Used 5/16" thick frames with plastic corner parts and had no problems installing the new screens. The window channels are made such that the screens install from the inside.

Yesterday I removed them so I could clean the outside upper panes , and now the *@! things won't go back into the upper channels. All 5 of them!! I remember when I made them they slid up into the upper channels quite nicely, now I have damaged 2 screens trying to cram them up there.

What's the secret here - am I getting too old to do simple tasks anymore?

It seems the plastic corners are now too thick to go into the channel. I even tried making a new narrow top frame rail (about 12" long) using leftover corners (brand new) and a straight section of one of the damaged frames and am having trouble getting that to go in as well.

Is there something I'm forgetting to do (can't think of what that would be)?

 

Raise the window to the halfway point, tilt them back into the room (holding it with your torso) and install the screens from the top down, and allow it to click into the top rail. Tilt the window back up and lock it in place.

 

Tried that. The problem is that the top frame member, which is 5/16 inch thick, will NOT to up into the upper 3/8 inch channel.

To add insult to insult, the War Dept. quietly asked if she could try it and she got the damn thing into place in less than 30 seconds. Then she told me the best man for the job is usually a women.

Hmpff!

The trick was to raise the window, hold the screen entirely OUTSIDE the window opening, tip the top of the screen into the opening, and slide the screen SIDEWAYS into one of the side channels (3/4 inch wide), then pull the bottom of the screen home. The top of the screen frame didn't need to go into the top channel at all.

Duh-h-h. I'm ready for the booby hatch.

 

But, you don't have to tell anyone. Your secret is safe, here. Hey, Ken.......