How to build and install a bay window in 5000 easy steps

[Don]

Hey, Guys. Well the time is here. The car is done and to appease the wife the bay window project is the first into the breach. I built the carcase of the window five years ago at least, the windows have been in the shop as well. The house is a "classic contemporary" which is doublespeak for "maintenance nightmare." This is what I'm having to do to even get to the window while protecting expensive new roofing. If you don't ever hear from me I've fallen through the glass house below, Omen style.

Keep in mind I'm afraid of heights if it's something I can fall off of, falling from something is different somehow, airplanes, gliders or hot air balloon rides are okay. Anybody similar?

Anyway, I'll keep the pictures coming as work progresses through the next few weeks (I hope), I've got to build a jib crane to hoist the affair onto the roof, I'm working alone for the most part.

Marty, I could use some help getting the floor panels up, 2 sheets of OSB.

The frame.
http://www.internetcp.com/gallery/data/503/medium/IMG_0304.JPG

What one has to do when one of the windows will not fit.
http://www.internetcp.com/gallery/data/503/medium/IMG_0305.JPG

After the routing to make one window fit.
http://www.internetcp.com/gallery/data/503/medium/IMG_0306.JPG

Step one, ladder.
http://www.internetcp.com/gallery/data/503/medium/IMG_0307.JPG

Step two, platform truss.
http://www.internetcp.com/gallery/data/503/medium/IMG_0311.JPG

Step three, more platform, making my way there
http://www.internetcp.com/gallery/data/503/medium/IMG_0312.JPG

Step four, getting there.
http://www.internetcp.com/gallery/data/503/medium/IMG_0314.JPG

I haven't worked this hard in a couple of years - it hurts.

All the best, Don

[Dr. Jim]

Nice Don,

You did say window right? Not deck?

So you are actually "making" the window?
How do you mount the glass in the frame for a weathertight seal?
Route some grooves and use some sort of sealer?
That has actually interested me alot over the years,...I would love to do some 'big' fixed glass windows.....but they are quite $$$ to buy from Anderson.

Whats your approach?

[Don]

Yeah, I told the wife to tell any inquisitive neighbors that we're building a stand to watch the races from.

My approach is on this project is pre-made single hung, window casements. Similar to Anderson, but not quite as pricey. No need to re-invent the wheel here. The framework will hold all of them closely together so they appear seamless. I'll get some more pics up as I take them.

dawjr

[thekl0wn]

Very nice! But is that just your scaffolding for the project, or are you putting a mini deck up there?

[Dagster]

I say keep the new structure as a game hunting platform. Just put up some cammo and you are good to go!

[Jammin]

My god, they make roof brackets that hook onto the roof under the shingles. They are very stable and safe if you use OHSA planks. As for building a window, I have never tried that, are you going with a LOW-E glass

[Don]

Hey, Jammin - I figured that some contractor would bring up the metal roof brackets. I wish I could have used something that easy but I needed a platform to work on, there will be lot of work going on here and with the glass house below I didn't want tools or me to lose footing.

We recently remodeled with all new windows, shingles and paint. I held off on this piece so I could do it. In the eyes of many I tend to over build, but by the same token, someone doing it for profit is not going to take the time to be as careful with the work that is not their trade. Case in point, the window replacements. My fourth picture shows fixed glass to the right of the top of the ladder. The fellows that did this work decided to remove the old 1/4" thick plate glass (24 x 48) popped it out and promptly dropped it on an entertainment center in the wife's bedroom. It exploded, glass everywhere. The piece of furniture ruined, glass in the carpet and bed. I'm not home. The wife, being ever helpful gave them the $800 Oreck vacuum cleaner to use. Glass going through the plastic impeller - well that piece of equipment will never be the same, and it's been repaired.

Anyway, here's my point on this and I'm off the track now. I've worked, trained and directed people almost all of my life. Most people have the best of intentions but unfortunately many will not put forth the effort it takes to anticipate all of the possible scenarios and the consequences. I train people, if possible, to look several steps ahead in any effort. It will serve them well in the long run. Seeing the big picture of a project and all of the steps needed is painful thinking, many are loathe to do it. You may agree that if you are one of the types that has this ability and agrees that it's important, you most likely will find yourself being the foreman, the owner, the project manager, the superintendent. Besides knowledge, an important aspect of this ability is anticipation.

Ask yourself why you simply decide to do things yourself, especially if money is not an issue. Very often this is the answer.

Most of my life, people stand back and wonder why I do things the way that I do - it always seems that there is a simpler answer in their minds. But when I break it down and ask them how they would have accomplished a particular important step, they usually hadn't thought that far ahead.

These might be interesting discussions in another thread. I feel that woodworkers, they guys that have it in their blood, are some of the sharpest guys around. More often than not they are extremely capable at several disciplines. Why do you think that is?

Oh, and to answer the question - yeah, I think it's low-e, argon filled, etc. I bought the windows about five years ago so I don't remember the detail of the sashes. They'll be so much better than what's there now. If you look you can see these window's seals have broken, they were some of the first insulated windows made in 77-78.

All the best, Don

[Terry Mac]

Nice project Don, do please keep the pictures coming of the progress.

Off topic question: Did you know there's an alligator in your shop?


Looking good, and looking forward to the next installment.

[Dagster]

Yeah, if you can please take a bunch of pictures. I'd love to see how this progresses.

[Don]

Hey, Guys. Time for some update pictures. I'm about 2500 steps into this one.

"Mantle" support
http://www.internetcp.com/gallery/data/503/medium/IMG_0322.JPG

Adding "Adornment"
http://www.internetcp.com/gallery/data/503/medium/IMG_0323.JPG

Ready for paint
http://www.internetcp.com/gallery/data/503/medium/IMG_0324.JPG

What? You don't have an elevator at your house?
http://www.internetcp.com/gallery/data/503/medium/IMG_0325.JPG

The "big" lift
http://www.internetcp.com/gallery/data/503/medium/IMG_0326.JPG

Butt cheeks were tight at this point
http://www.internetcp.com/gallery/data/503/medium/IMG_0327.JPG

Finally, the heavy stuff is in place
http://www.internetcp.com/gallery/data/503/medium/IMG_0334.JPG

Time for a beer and watching the pond from the "gallery"
http://www.internetcp.com/gallery/data/503/medium/IMG_0336.JPG

Next step, copper roof

All the best

[woodman43]

Looks great Don. I really like the pond.

[Terry Mac]

What size winch is that hauling up your frame? Would you tell a little more about your setup there for the frame raising. Appreciate it.

That's gonna be a nice addition Don.

[Don]

Hey, Guys. Thanks for the good words. Terry, it's one of those Horror Freight 880lb hoists. I have several of them around for stuff, they're cheap and work pretty good. The hoist is pretty simple, not like my first incarnation - we won't go there. Basically a couple of 16' 2x6's tied together as frame rails. They are attached to the deck framing on both ends, the hoist is suspended at the top with a piece of electrician's unistrut, which just fits in the hoist's loops. Cable down to a return pulley and back up. This gives the maximum pull with the slowest speed. I'll have to say it works perfectly. I waxed the rails with Johnson's paste wax. The slide simply sits on the frame rails and is winched up or allowed to slide back down, its keyed to the interior like railroad wheels. It's cantilevered forward so it can't tilt backwards with a load on it.

To work on the roof I simply load the tools and safely climb the ladder, then hit the button and it brings the stuff to me and then takes all the tools down at the end of the session.

This is the simplest apparatus that I could come up with for the purpose. A straight up and down would have required more height, bracing and track work. This worked out to be exactly as planned. A rare occurrence as I get older. Anyone that wants more pictures or closeups, speak up.

All the best, Don

[Dagster]

Awesome work! Love the window lift. Keep the pictures coming. I'm dying to see the copper roof.

[Don]

Here's more progress

Ready for the sheathing
http://www.internetcp.com/gallery/data/503/medium/IMG_0343.JPG

Sheathing and fascia in place
http://www.internetcp.com/gallery/data/503/medium/IMG_0348.JPG

Custom bent drip edge
http://www.internetcp.com/gallery/data/503/medium/IMG_0363.JPG

Drip edge detail
http://www.internetcp.com/gallery/data/503/medium/IMG_0364.JPG

dawjr

[woodman43]

Man that coppers is perty! I love the look of copper on things when it is new, but wish there was a way to keep it from turning brown.

[Don]

We'll keep an eye on it and most likely put that acid stuff on it that accelerates the green patina. If anyone has seen that stuff anywhere lately let me know. Seems like I saw a bottle at one of the home box stores, years ago though.

dawjr

[Cocobolove]

They make a copper colored metal roofing material. Never changes color. It will stay shiny copper colored for at least 25 years. A lot cheaper too. Any metal roofing company should be able to get it. I know Metal Sales has it. If you want the green look, I can check with my suppliers and find out where to get the acid. ( I do outdoor construction, mostly metal roofing)

[Cocobolove]

Nice Don,

You did say window right? Not deck?

So you are actually "making" the window?
How do you mount the glass in the frame for a weathertight seal?
Route some grooves and use some sort of sealer?
That has actually interested me alot over the years,...I would love to do some 'big' fixed glass windows.....but they are quite $$$ to buy from Anderson.

Whats your approach?


If you want to do a large plate glass window, it's easier than you would think. I would suggest getting a double paned glass with argon gas and low E (IG unit). You just have to get the glass cut to leave about 1/8 inch on each side of it(measure the opening and allow 1/4 inch for the height, and the width) install a 3/4 board inside to match the width of your wall, then apply a good silicone caulk to the board. Set the IG unit in the opening. If you have some small pieces of rubber they work best, but wood wedges will work too, place them under the IG unit to level it up. I like to use 3/4" quarter round as a stop on the outside. Apply a good bead of the silicone to the quarter round and squish it in place. Finally nail it with small trim nails, paint, and you're done. Big solid IG window unit.

[Don]

Hey, Coco. We really didn't know what we were going to want in the way of color. I bought the copper several years ago in anticipation of this project. If you will look into the acid it would give us that option as well. Thanks for the input.

dawjr

[Don]

Hey, Guys - Just about got her done and ready to take down the roof scaffolding.

http://www.internetcp.com/gallery/data/503/medium/bay.jpg

Here is why it has taken so long, doing work on the front of he house too. The front porch was built over a year ago and I had the guys come back and help me with the concrete.

http://www.internetcp.com/gallery/data/503/medium/porch2.jpg

http://www.internetcp.com/gallery/data/503/medium/porch1.jpg

http://www.internetcp.com/gallery/data/503/medium/porch3.jpg

dawjr

[Don]

Hey, Guys. Several months in the making, here are the final pics of the bay window project.

http://www.internetcp.com/gallery/data/503/medium/IMG_0465.JPG

http://www.internetcp.com/gallery/data/503/medium/IMG_0466.JPG

http://www.internetcp.com/gallery/data/503/medium/IMG_0467.JPG

http://www.internetcp.com/gallery/data/503/medium/IMG_0468.JPG

It's quite a difference from;

http://www.internetcp.com/gallery/data/503/medium/IMG_0308.JPG

Cool, huh?

dawjr