I will be making screen frame for a lot of windows. What is a very effective tool that can cut them fast and crisp?

 

Diamond metal blade for miter saw, the fiberglass blades will tend to leave burrs!

 

Use a miter saw with a carbide-tipped blade. It will cut through an aluminum screen frame like butter with only minor burrs to remove with a file or utility knife. I just modified a window screen for a different size and it worked perfectly.

 

But if you want to eliminate all burrs, the diamond blades are amazing, a bit more money but once you try them you wont use anything else.

Cuts like warm butter and they last forever, never get dull!

https://www.dewalt.com/products/acce...w-wheel/dw8500

 

I have to chime in on this since I do in fact repair and fabricate screen and windows frames.

Both Marq and Toyln are correct.

But I don't have the luxury of my store providing me with the "proper" tools. For the past seven years I've used an ordinary stiff back saw and miter box (I do not use hack saw). The same one. Never needed to replace it. It works and just a quick swipe of a file remove any burrs. At this point I would not even want anything else. Save yourself some money.

Suggestions:

If the screens are all the same size, make one single template and use that as your guide to make all the others.

Use a 45 degree corner if possible . They are a much stronger frame.

Do not pull tight on the opposite ends. Just keep the cloth firm. A little bit of slack is actually good. You do not want any twist in a finished screen.

Avoid using aluminum if possible. Fiberglass cloth is best and cheaper. Or pet safe if need be.

If the screens are 48 inches or longer you might want to use a midsection stiffener bar.

Try to use a spline that is slightly thicker than recommended. Stretch it to make it fit.

SWISCO.COM is a good source for supplies.

Good luck.

 

A miter saw with a fine tooth plywood blade works fine. I assume you will be using rolled aluminum screen frame (thin) versus extruded (heavy). If you are going to use a handsaw and miter box, you might want to use these corners to eliminate mitered corners.https://www.lowes.com/pl/White--Wind...ent=4294820092

 

Again as suggested a mitered corner with a metal insert is much stronger and UV proof. Plastic will deteriorate, become brittle and break.

When I fabricate new frames I almost always opt for a miter corner.

 

Agree, Norm....but the straight cut with those corners might be easier for a DIY.