How to Make Window Screens: Materials, Tools, and Steps

Making window screens from scratch involves assembling frame pieces, stretching mesh material across the frame, and securing it with rubber spline. The process takes 45-90 minutes per screen for first-timers, with material costs running $15-30 per screen. This guide covers what materials and tools you need, the basic process, and when DIY makes sense versus ordering pre-made screens.

Materials You Need to Buy

If you are planning on building your own screens, you will need to visit your local hardware store and pick up some supplies.

Aluminum frame stock: 8-foot lengths cost $3-8 each. For a 30"x48" screen, you need two pieces (covers 13-foot perimeter). Choose frames with spline grooves matching your spline diameter (0.140", 0.160", or 0.180").

Screen mesh: Buy by the roll or foot. Fiberglass costs $0.50-1.50 per square foot, aluminum runs $1.50-2.50, specialty meshes cost $2.50-6.00. A 50-foot roll of 36"-wide fiberglass ($60-90) handles 12-18 average screens.

Spline (rubber cord): Match your frame's groove width. A 250-foot roll ($12-20) serves 15-20 screens. Buy quality spline—cheap versions become brittle quickly.

Corners: Plastic corner pieces ($0.25-0.75 each, need 4 per screen) or metal corner keys ($0.50-1.00 each).

Mounting hardware: Pull tabs for double-hung/sliding screens ($1-3 per pair), clips for casement screens ($0.50-2.00 each, need 4-8 per screen).

Tools Required

You will also need to either rent or purchase a number of tools in order to build screens on your own.

Essential tools ($50-100 total if buying new):

• Spline roller tool ($5-40) - crimps spline into grooves

• Utility knife with fresh blades ($8-15)

• Tape measure, 25-foot metal ($10-20)

• Hacksaw or miter saw ($10-50)

• Framing square ($8-15)

Optional but helpful: Assembly table or flat workspace, corner clamps, spline groove cleaner.

Basic Process Overview

Here are the basic steps that go into making your own window screens:

Step 1: Cut frame pieces to length based on your measurements. For a 30"x48" screen, cut two 30" pieces and two 48" pieces, accounting for how corners will connect (corner pieces add length).

Step 2: Assemble the frame by connecting corners with plastic corner pieces or metal keys. Use your framing square to ensure all corners are exactly 90 degrees. Slight irregularities cause screens that don't fit windows properly.

Step 3: Lay mesh over frame with 2-3 inches of excess on all sides. Center the mesh so you have equal overhang around the entire perimeter.

Step 4: Install spline starting at a corner. Use the convex wheel on your spline roller to press mesh and spline into the groove simultaneously. Work around the entire perimeter, pulling mesh taut (but not overly tight) as you go.

Step 5: Trim excess mesh with a utility knife running along the outside edge of the spline. Fresh, sharp blades cut cleanly without tearing mesh.

Step 6: Install mounting hardware and parts (tabs, clips) at appropriate locations based on your window type.

Step 7: Test fit the screen in your window before building more screens. Verify it fits properly and all hardware functions correctly.

When to DIY vs. Buy Pre-Made

There are times where it might make sense to build your own window screens and when you might want to consider purchasing some new ones.

Build screens yourself when: Replacing 8+ screens, you have unusual window sizes, you enjoy DIY projects, or the budget is very tight.

Order pre-made screens when: Replacing fewer than 5-8 screens, you're time-constrained, you lack tools/workspace, or you want guaranteed professional results.

When to Make Window Screens

Making window screens is a learnable DIY skill that saves money on large projects. The process requires attention to detail, proper tools, and patience during your first few screens.

For homeowners comfortable with basic tools and willing to invest 12-15 hours, DIY delivers significant savings. For those who value time over cost savings, ordering pre-made screens makes more sense.

Ready to start? Check out our guide to window screens so you can determine whether or not you want to make your own.