How to Cut a Storm Door Window

  • 5-10 hours
  • Intermediate
  • 100-500
What You'll Need
Replacement glass
Glass cutter
Cutting oil
Permanent marker
Silicone sealant
Hand Tools (screwdriver, pliers)
Leather gloves
Tape measure
Yard stick

If the window on your storm door breaks, it doesn't mean that you need to replace the entire door, but just the storm door window. Cutting glass for a storm door is no different than cutting glass for any other purpose. A storm door window can be made of either glass or plexiglass (a plastic product that mimics glass). Regardless of the actual material, creating a new window is not difficult. It does however take a steady hand. Frequently, it will be more difficult to remove the glass casing than the actual glass. Here you will find the information needed to cut and replace a storm door window.

Step 1 - Remove the Window Casing

If the window has broken in your storm door, you will need to remove the broken glass and prepare the casing for new glass. Remove any glass that you can without disassembling the window casing. Make sure you put on the leather gloves before removing glass. Place the glass in a metal or plastic bucket for disposal. Carefully inspect the casing for the glass to determine how to remove all the glass. Use the hand tools to disassemble the casing.

Step 2 - Prep the Casing

Prepare the casing to receive the new glass by removing any adhesive or existing caulking. Consider replacing any seals or weather stripping while you are at it.

Step 3 - Preparing to Cut the Glass

Make sure that you purchase a large enough piece of glass to cover the window. Take measurements of the casing inside any edges to get the exact dimensions needed to replace the glass. A piece that is too small will fall out and you will have to repeat the process. A piece that is slightly too large will be difficult to recut. Measure twice, even three times before attempting to cut the glass.

Lay the glass on a flat surface that is covered with a cloth, such as a towel or rug. Mark your measurements with the marker, using the yardstick to measure the dimensions that are needed. Make sure that the glass is free of any residue before scoring the glass. The point is not to cut the glass, but to score it so that it breaks evenly and straight. Once you have marked the needed dimensions, use the yardstick as a guide as you score the glass.

Step 4 - Cutting the Glass

Now that you are ready to score the glass, dip the cutting tool in the oil. Run the cutting tool along the edge of the yardstick with firm, but not forceful pressure to score the glass properly. If you feel drag like the glass is gritty, you are either pushing too hard, the tool is not well oiled, or there is dirt or residue on the glass. Stop and double-check all of these things. It may be helpful to practice on a piece of scrap first. Once you have one edge scored, you will want to snap the glass along the score line. Do this along all other edges, and install the window as the old one was.