Replacement Window Sash Kits save money on heating costs. Replace drafty old windows with energy efficient low-e glass and insulated sashes

Tools Needed:

Level
Measuring tape
Putty knife
Utility knife
Flathead screwdriver
Small finishing nails
Roofing nails
Hammer
Miter gauge and protractor
Saw
Safety glasses

Before                      After

How to Measure:

1. Measure the width of your existing sash opening from the inside of the wood on the left jamb to the inside of the wood on the right jamb in three different places - top, middle, and bottom. Record the narrowest of the widths.

2. Measure the sash opening height from the top jamb to where the exterior of the bottom sash sits on the sill when fully closed. Measure at the left side, middle, and right side. Record the shortest of the three heights.

3. The standard sill angle for our sash kits is 14°. Check the sill angle using a miter gauge and protractor, or other angle measuring tool available at the hardware store. Any sill angle between
5° and 14° is available but must be specified when you order.

Formulas:
Used to determine glass and sash sizes.

Glass Width
Glass Width = Sash Opening (S.O.) - 4.125"
Minimum foam compression = S.O. - 4.5"
Maximum foam compression = S.O. - 4"

Glass Height
Glass Height = (S.O. - 6.0625") / 2

Glass to actual sash size offset
Top sash = Width = (glass) + 2.375
Height = (glass) + 2.690

Bottom sash = Width = (glass) + 2.375
Height = (glass) + 3.878

Custom Sizes
in 1/4" increments.

Minimum size:
16" x 14" glass size
Maximum size:
40" x 36" glass size

Sash kits can adjust to fit an opening width by as much as 1/4" via jambliner compression. The sash opening height cannot vary from the sash opening size.

Installing the Sash Kit:
See the installation and finishing instructions for detailed information.

Carefully remove inside side stops from existing opening, using a putty knife. Save for reinstallation. Remove old sash.

Remove head parting stop. Check opening for square and plumb with level and measuring tape. Adjust and shim as needed.

Apply head gasket to top of window head jamb. Apply jamb clip according to the installation & finishing instructions using roofing nails.

Prepare balance assembly for installation, making sure block and tackle, balance soe, and dust block are complete. Start at the top and snap jambliner into clip. Some trimming may be required.

Adjust balance shoes to center point of balance. Use a flathead screwdriver to adjust and turn to lock for top sash block and tackle. Bottom block and tackle should be 2/3 from the top.

Install top sash to outer track. Set tilt pin on sash into the balance shoe. Keep the sash horizontal to seat pins into the balance shoe. After seating, retract tilt pins and tip sash to a full vertical position. Push sash over the balance tracks of the outer track into the sliding position. Repeat for the bottom sash, inserting sash in the inner track.

Locate proper position for head stop assuring the stop weather-strip is making contact with the sash. Apply head stop with screws supplied in sash kit. Replace original inside stops with finishing nails. Check sash for operation and tiltage.

Complete Sash Kit

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