Are you ready to replace your drafty old windows with new energy-efficient units? You’ll be glad to know that you don’t have to tear off interior moldings or disturb exterior trim and siding. We’ll show you ways to mount replacement windows inside your existing window jambs. These methods will save you the hassle and mess of tearing out the old window and trim.
In this article, we’ll show you step by step how to remove the old sash from double-hung windows and mount either a new
sash kit or a wood or vinyl replacement insert inside your existing window jamb. Even a beginner can do it.
Both the sash replacement kit and the wood or vinyl replacement insert mount inside your existing window jamb, in the place that was occupied by the old sash. They both fit in the space between the outside stop, called the blind stop, and the removable interior stop (see Fig. A). The sash replacement kit is designed to replace the sash in double-hung windows only. Wood or vinyl replacement inserts, on the other hand, are self-contained units with their own jamb and sash, and can therefore be slid into almost any type of window jamb. They are available as double-hung, sliding or casement-style windows.
Option 1: Wood Or Vinyl Replacement Inserts
For a maintenance-free window that doesn’t require any painting or staining, consider vinyl replacement windows. Some companies even make a simulated wood grain interior. Since wood or vinyl replacement inserts have their own jamb, they can be installed in window jambs that are slightly out of square. Ask your window dealer for help measuring, though, since you’ll have to downsize the window slightly to fit.
Shopping for replacement windows is a little trickier than buying sash kits because the quality of the windows varies dramatically and many are available only to contractors. The Vetter window we ordered cost $225 and arrived in about three weeks. Make sure to inspect and operate an actual working model of the window before you order. Look closely at details like the locking system, weatherstripping, and sash and frame joints. Then consider the overall appearance. Some windows, like ours, have narrow vinyl sash parts that allow more light and a better view than windows with wide sash frames.
FIG. A WINDOW PARTS
Buyer’s Guide
The following companies manufacture vinyl replacement windows. Call for the retailer nearest you. For a list of companies that sell wood replacement windows.
Crestline Windows And Doors: (800) 552-4111. www.crestlinewindows.com
Kvw Division Of Kolbe & Kolbe Millwork Inc.: (800) 955-8177. www.kkvw.com
Vetter Windows & DOORS: (800)VetterR2. www.vetterwindows.com
Your Old Jamb Must Be Solid
The window replacements we show must be installed in a solid, rot-free jamb. Inspect your old window frame carefully for signs of
water damage. Pay particular attention to the sill. Probe with a screwdriver to uncover hidden soft spots. Normal exposure to rain and snow often causes the exposed parts of poorly maintained windowsills or the lower sections of the exterior trim to rot. An experienced carpenter can usually repair these areas with sections of new wood or you can use an epoxy repair system. Rot along the top or interior parts of windows, including the window jamb, is more difficult to repair and often signals a bigger problem. Don’t mess with repairs. Plan on tearing out the entire window and installing a new one.
Measure Carefully
There’s nothing worse than discovering that your nonreturnable, custom-sized window doesn’t fit.
Option 2: Double-hung sash replacement kits
If you want to retain the authentic wood look of your old double-hung windows, sash replacement kits are the best option. You can order the sashes with grilles to match the rest of the windows in your house and paint or stain the wood. (You can choose grilles that either snap in or are glued to the glass.) But your old window jamb must be square and rot-free. Measure diagonally. If the diagonal measurements differ by more than 1/2 in., the new sash won’t seal properly and you should replace the window or use a vinyl replacement window instead.
Double-hung sash replacement kits consist of two new wood window sashes, two vinyl jamb liners and installation hardware. They range in price from about $200 for a basic window with a snap-in grid to more than $400 for windows like ours with simulated divided lites. Features like energy-efficient low-E glass and maintenance-free exterior cladding are available for an extra cost. Contact one of the manufacturers listed on this page for more information and to find out where to order windows in your area.
CAUTION:
Houses built before 1978 may contain lead paint. Before disturbing any surface, get a lab analysis of paint chips from it (about
$5 per sample). Contact your public health department for information on how to collect samples and where to send them.
Buyer’s Guide
Here are a few companies that sell double-hung sash replacement kits. Check your local lumberyard or home center for other
sources.
Caradco:(800)238-1866. www.caradco.com
Kolbe & Kolbe Millwork Inc.:(800) 955-8177. www.kolbe-kolbe.com
Marvin Windows and Doors:(888) 537-8266. www.marvin.com
Measure the width between the side jambs at the top, middle and bottom and record the smallest measurement. Measure all the way to the jamb, not the blind stop or parting stop (see Fig. A). Now measure the height from the top jamb to the sill (see
Fig. A). Measure both sides and the middle and record the smallest measurement. Finally, determine the sill angle (Photo 1) and specify this when you order a sash replacement kit to make sure the jamb liners fit tight to the sill. This step isn’t necessary for ordering wood or vinyl replacement inserts. Keep a record of all correspondence with your window supplier and ask
for a written confirmation before the windows are ordered so you can double-check the sizes.
If your house was built before about 1940, you’ll likely have double-hung windows with sash weights and cords like the ones shown in this article. Newer double-hungs may have springs or jamb liners instead, but once these are removed, the installation process is the same.
Option 1: Wood Or Vinyl Replacement Inserts
Start your replacement insert installation by removing the interior stop, sash and parting stop. The parting stop is usually caked
with paint and difficult to remove. Use a pliers (Photo 3) to break out the lower section. If the upper sash is stuck, pry or break out the upper section of parting stop with a chisel. If your windows have spring balances or metal jamb liners rather than sash weights like ours, start by removing the interior stops (Photo 1, above left). Then look for the screws or nails that secure the sash hardware and remove them. The goal is to remove all hardware back to the blind stops (Photo 2 above). You don’t have to worry about dinging up the jamb and sill because they’ll be covered. If your window has a sash weight cavity, stuff it with insulation.
