Trimming it down

It was going to be tight fit. To give me an extra 6mm on the width I took the cover off one of the weight boxes, planed the rebate off and fitted some breathable membrane (roofing felt) on instead.

The top needed trimming as well. It's designed to allow for a bit trimming but I ended up having to trim more than I'd planned for.

Then It Went HORRIBLY WRONG

I nearly cried after I just checked the size of the old window to see how much plaster I'd have to take off.


The new window was too small, how can that be? what went wrong? How could I possibly recover from this.


I tracked the problem to the spreadsheet I had done to work out the dimensions. I found I had subtracted the size of the outer lining lining lip instead of adding it, resulting in the window being 80mm too narrow and 40m too short. OH S*#T.





After I'd calmed down I checked the other window sizes and Lady Luck came to visit. It should fit in one of the other rooms. A tight fit and a little too high but workable. Phew!

I did a little investigating with a crow bar to get the exact sizes of the brick work.

Getting ready to install

With the new lead weights collected I was ready for installation - Almost.

The Lead bought in one meter lengths need cutting down to the right size. The circular saw cuts it nicely. I also cleaned up and painted another 4 iron weights.

The weights dividers fitted in...

And the back of the weight boxes fitted. Made from 6mm ply.

I then did a trial fitting of one sash to make sure the weight would fit and to practice the procedure. To do this I fitted the cords using 25mm no.6 screws, 4 off on each cord.

With everything ready it was time to start ripping out the old window.