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These general instructions are provided to give an idea of the processes involved in “retrofitting” your windows. More detailed instructions, tips and videos accompany purchase. Also, you can order the custom Magnum High Performance Wood Window with the WindowLogic Weatherstripping kit already installed.

Tools Required

Tape Measure
Marking tool (sharp pencil)
Utility knife
Caulk gun
Saw horses
Saw capable of ripping
Straight edge
Various screw drivers
Miter box
Metal shears
Router 1
Router 2
Slotter cutter (router bit) (available from Heirloom)
Mortise cutter (router bit) (available from Heirloom)

Tools Desired

Bar clamps
Circular saw
Saw guide (can be home made)
Power drill with drivers
Power miter saw
Oscillating saw

Tool Description

Note on tools:
There are two groups of tools listed a) tools required and b) tools desired. Many people do not own all the tools in either category. However, most can be found at your local tool rental facility, can be borrowed, or can certainly be purchased. We have had great experience and saved a great deal of money purchasing tools from pawn shops. If one identifies his needs in advance and arms himself with “new pricing”, tools and equipment can be purchased at 25% – 40% of retail. As a matter of fact, we only buy used if the price is less than 33% of retail (or a bit higher for hard to find items or those in exceptionally good condition). If the vendor will not meet your terms, move to the next shop, there are usually dozens in metro areas.

1. Remove Existing Sash

Operation time 8-10 minutes for non-sealed traditional window. Add more time if sash are painted shut or other weather-stripping has been applied.

  1. Remove interior stop (1) from sides and head. Set aside for later use.
  2. Remove lower sash (2). Set aside for later use.
  3. Remove parting stop from sides and head. Discard.
  4. Remove upper sash and set aside for later use.
  5. Scrape interior surface of blind stop (5) to remove paint and other debris. It may be desirable to scrape other exterior surfaces at this time since they are readily accessible.
2. Prepare Balances (reusing original weights option)

Operation time 10-20 minutes.

  1. Locate balance access covers and remove them from jamb side. Set aside for later use.
  2. Remove ropes from weights, remove weights. Set aside weights for later use.
  3. Inspect pulleys and lubricate if necessary
  4. Feed new rope or chain over pulleys, into balance cavity and reattach to weights.
  5. Knot or otherwise prevent chains from falling back into cavity.
  6. Reapply access covers.
3. Prepare Sill

Operation time 8-10 minutes.

  1. Scrape deteriorated paint and other debris from sill.
  2. Measure distance between jamb sides (sill length).
  3. Cut sill Bulb Seal Retainer to sill length. Set aside
  4. Cut sill wrap to sill length.
  5. Create a “caulk bed” approx 1″ vertically and horizontally from Sill/Jam side joint.
  6. Lay in flashing (not shown)
  7. Repeat caulking process atop flashing
  8. Caulk Sill/Prime sill joint
  9. Lay in Sill Wrap and embed firmly into caulk
  10. Flashing and sill will be fully covered in subsequent operations.
4. Prep and Apply Jamb Liners

Operation time 15-25 minutes.

  1. Cut bottom of two jamb liner sections at same bevel as sill
  2. Sit the bottom sash back into the jamb and mark where the approximate center of the meeting rail lands on the jamb.
  3. Cut top of those jamb liners so their tops are approximately at the meeting rail mark from step 2
  4. Remove the sash and temporally screw the two bottom jamb liner sections in place.
  5. Cut the two other jamb liner sections to length to fill the upper portion of the jamb
  6. Create a template or otherwise mark where the pulleys protrude from the jamb and using a utility knife cut the upper jamb liner sections to accommodate the pulleys.
  7. Caulk and screw three of the four jamb liners in place, leaving one of the lower jamb liners uninstalled to facilitate installing the upper sash later.
5. Sash Preparation

Operation time 20-30 minutes.

  1. Check sash edges and meeting rails for joining nails and other metal obstacles and remove if found to prolong life of cutting tools
  2. Saw 5/16″ from each side of each sash and 1/4″ each from the top and bottom rail
  3. Route a 7/16″ H x 3/16″ D dado approximately centered, the length of the meeting rails
  4. Apply the fin seal carrier to each side of both sash using adhesive caulk and drywall screws, staples or trim brads. Do not put fasteners into area of rope plows.
  5. Use utility knife to remove carrier material from rope plow. If necessary enlarge knot hole to accommodate knot.
  6. Apply meeting rail bulb seal, supplementing the pressure sensitive adhesive bond with fasteners if desired
6. Install Sash

Operation time 10-20 minutes.

  1. Attach rope or chain (other other balance method) to upper sash and raise sash to closed position
  2. Apply last jamb liner section to jamb
  3. Sit lower sash into position and check for proper fit at meeting rails and saw material from bottom rail as necessary
  4. Attach rope or chain (other other balance method) to lower sash, move to closed position
  5. Reapply interior stops
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