Part of why I haven't posted much here has to do with me replacing all my windows in my house. Even though its a house project it really effects the shoo as having 9 large windows stored in the shop that are now gone really makes a difference in cleaning it out. Which is one of my goals with this thread.
Here's some pics just because im proud.
So fun story about sizing replacement windows. Got online and found out how to measure. Easy peasy. Measure height and width in 2 or 3 places to find smallest point. Then subtract 1/4 inch from height and width to ensure fit.
So take my measurements to menards and order windows. Guy is reading back my measurements and they sound wrong. I ask whats up with that. He says the computer automatically removes a 1/4 inch. I say i did that already. Lets fix it.
He says "well if the windows are too big and dont fit you have a major problem and they cannot be returned" That made me nervous as im spending like 3k here on windows...i agree with him and we dont change it.
Well guess what... The windows didn't fit. They were too small and went right past the exterior stops (which is what holds in a pocket frame window in case you havent done them)
So i was still stuck with 3k of unreturnable windows that didnt fit right. Thankfully i came up with a simple solution. Cut out all the exterior stops and make them bigger.
The orignal stops were about half inch and the windows almost fit. So i cut them out with a combo of circular saw and recip sawing and replaced them with .75 plywood.
This created another stupid problem. All my window trim was cladded with nice custom bent aluminum and my house is already vynil sided. So i had to rio off all the aluminum trim cladding and replace.
I did learn some neat new skills and got to play with some fun and unique tools at least. Oh and spend a small pile of money. Oh well. Here's more photos.

Those show the new exterior stops and making them flush with the trim so the new aluminum cladding would go on easily as possible for me.

Measure with a combo square and transfer to material instead of trying to use a tape measure.




Bend, test fit, notch, bend notch and fit.



Some shots of my workflow area. 10ft trim bender (rented) then outfitted a worktable i got free from trash as a metal working bench. Built a neat holster for my nibbler. Extended the 4ft table to 8ft with some 2x4s. The gap in the middle of the 2x4s was useful for ripping it down. Also lots of clamps to keep the trim coil rolls managed.
Shot of and after before. Makes a huge difference and i hate painting so big plus there.

Some finished shots. That big 3 peice window was a bear to move. Its all 1 peice and probably weighed a million fragile pounds (honestly 200 tho) and was nearly $900 bucks on its own...
And for fun here is how 1 guy movea a 100 pound 10ft long trim bender around the house
Thats a 6 pnumatic wheeled, 2x4 framed homemade garden cart. Its 54 inches long and is great for moving weird heavy stuff. I had a 700 pound concrete slab on there once when we moved an air conditioning unit.
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