making double gglazed windows

[brokenbiker]

i have just been on the phone with a mate who is building his own shed.

so far he has just drawn it up, but he wanted to know if i could make him steel framed double glazed window units if he supplied the materials and plenty of tea and sandwiches.

never even thought of making window frames before, let alone double glazed units.

the only thing i can think of at the moment, is when they are done i could purge them with nitrogen to stop them misting up inside (got the idea from my rifle scopes)

what would be best material to use. metal will be mild steel but do i use box, angle, flat bar?

how would i attach the glass?

 

[chunkolini]

I would suggest he buys them, possibly from a reclamation yard.
This sounds like one of those 'little jobs' that could become a nightmare.

 

[Dev]

Dont 'proper' double glazed windows have a vacuum between the panes?

 

[madkayaker]

Second hand would be the way I would go.get windows first then build shed to suit.

 

[outofthefire]

Keep an eye on freecycle second hand windows come up quite often.

 

[brokenbiker]

yes, proper ones have a vacuum, but I don't have facility to make a vacuum, but I can get hold of nitrogen.

I have made a basic design that uses a box section frame, with a strip of flat bar plug welded to the inside of the box section fram, so there is a recess for the glass to fit in.

then it would be covered in sealent, glass put on and more flat bar welded as a lip over the glass, or possibly bolted then tack the bolts so they cant be removed, as welding so close to the glass could cause issues. then sealent around the edges. drill and tap a hole, purge with nitrogen, then put a bolt wrapped in ptfe in the hole to keep the nitrogen in...

on second thoughts, im gonna tell him to buy them. typing that out has made me realise how many things could go wrong...

 

[Lawnmowerboy]

more than likely you'll crack the glass instantly when you spot heat it. Hold a lighter on a beer bottle for a few seconds...

 

[brokenbiker]

yeah that is the part that was worrying me

 

[tlovatt]

You buy double glazed units from the glass shop, they will give you units that are purged and selaed so you install them as a single, 1" (or so) thick unit.

Make the frames, then take them to the shop to have the glas cut to size and fitted. Personaly I would make a frame with flanges front and back, but make the top bolt on so the glazed units can slide in then hold the top on so the screws are hidden when the window is shut.

 

[brokenbiker]

You buy double glazed units from the glass shop, they will give you units that are purged and selaed so you install them as a single, 1" (or so) thick unit.

Make the frames, then take them to the shop to have the glas cut to size and fitted. Personaly I would make a frame with flanges front and back, but make the top bolt on so the glazed units can slide in then hold the top on so the screws are hidden when the window is shut.

that is a better design than mine.

he tells me he already has glass for 2 windows and your idea means no welding near the glass.

 

[tlovatt]

If he already has some of the glas, you may still be able to get a shop to trim it to final size and make them into selaed units - but to be honest I was amazed how cheap glass is.

 

[brokenbiker]

yeah its not expensive.

I think he wants me to make the frames to fit the glass, then he is going to make the shed to fit the frames...

still think im gonna tell him to buy frames instead though

 

[Wendelspanswick]

Try a few local glazing companies, they normally have skip loads of glazed units removed from houses and quite often miss measured new units. Normally free or for beer money.

 

[brokenbiker]

cheers, will have a look into that

 

[chunkolini]

Brokenbiker says
"on second thoughts, im gonna tell him to buy them. typing that out has made me realise how many things could go wrong... "
I reckon best idea is punch him on the nose and run away.
Next up he will be asking you to repair his exhaust pipe (tube of rust and holes) for beer money.

 

[brokenbiker]

nah he knows not to ask for anything for free. the answer is always no unless its for family, and even then some things get charged for a bit. especially the 4 meter wide collapsible gate that needs to be out of sight when its open.

that one isn't being done for free

 

[KemppiFrog]

My sculptor client just converted a garage to a workshop. She is sensitive to the cold and needed double glazed glass all round and max natural light. So, four fold steel doors for the big opening + two other doors and a window with two leaves.
Doors had a 50cm high solid panel at the bottom, rest glass. The solid bit helps the stiffness of the doors. We bought the glass units in London as half the price compared to here. Doors were all 30mm sq tube with a 12mm flat lip flush with the outside, to retain the glass. Min 5mm gap round the glass and glued in with silicon. If the glass touches the frame, you will get trouble later.

For fitting next week: A room divider with four glass panels and a steel door to one side with glass to the same height as the divider. Again, the bottom panel contributes diagonal rigidity and, as he wanted angle for the frames (saw the idea in a deco mag) the cross pieces are tube for torsion.
Divider is angle frame with t section between the panels. Not double glazed as inside the house.

 

[FranV8]

That will need pictures! Sounds very cool.

 

[KemppiFrog]

That will need pictures! Sounds very cool.

If that was for my post, I will get some on Monday. They are off for the week-end and the shutters cover the openings.

 

[normspanners]

The problem with making window frames is that the frame needs a thermal break IE the inside is not directly connected to the outside if it doesnt have the thermal break it will condensate on the frame on the inside, Gallons of it. old ally frames used to have the problem the later ones frames where joined inside to out by bonding with resin