Most of the home improvement projects that I tackle seem like they should be way easier than what they usually end up. Such was the case as I set out to replace two old, louvered-style aluminum frame windows in our basement with much more energy efficient and attractive vinyl sliding windows.
We’re trying to spruce up the main space in the basement but before we try to do something with the walls it might be nice to upgrade the windows first. Neither of the windows even work (one is totally covered up) let alone keep out the cold air in the winter. So the decision to replace them is a must. This is what they looked like.

And even uglier up close.

So the only real issue was whether to attempt this project by myself or to pay a pro. Well if you’ve followed this blog very much you know how I am about paying others (generally my last option) but when power tools are required to complete a project, it’s usually makes it a slam-dunk. And not only that, how could two things so relatively small be a big deal? Well I was about to find out.
The first hurdle that I had to clear was figuring what actual size of window to get. I was going to go with stock units and not custom-order so there was a limit on choices. My options were basically 15″ X 32″ or 17″ X 32″ based on the local Lowes. Unfortunately, I didn’t really know what the rough opening would end up being since it would be hard to know what amount of concrete would be left after I broke the aluminum frame out. And sure the smart move would have been t0 wait until I got them totally out before buying the new ones, but where’s the fun in that? It’s much more fun to guess. So I bought a couple of 17″ X 32″ ThermaStar slider units from Pella.
Next, and obviously the biggest hurdle, was how to actually get the frames out. After all, those babies were part of the concrete and firmly embedded. I’d never done this before, but some of the info that I got from the internet mentioned chiselling all around the frames, cutting/breaking them apart into four pieces and then finally loosening them from the concrete. Sounded good to me.
The first window I followed the above process, but when I finally broke the sill out it left behind big uneven chunks in concrete so I had a serious amount of grinding to try and get it close to flat. I wasn’t anticipating grinding the concrete for the sill, but what was worse was that the rough opening to the left and right was more like 31-1/2″ in a few areas, not the 32″ width that was a minimum. So then I had no choice left but to have to grind and make the rough opening bigger.
Now I could bore you with the next few hours of dirty, dusty, forearm-busting, tedious grinding on the concrete, but suffice it to say that I managed to get through it. But boy you talk about concrete dust everywhere, it was a mess in that basement. (I think I can relate to ancient Roman sculptors now.)
This is what the rough opening looked like after grinding.

If you look real closely at the picture there is no header at the top of the opening that’s the sill plate. I suppose a frame buried into the concrete really doesn’t need to have much additional support. So then I had to construct a header and figure a way to tie the header into the underside of the sill plate to keep the weather out. Here’s what I came up with. The large flat piece is a section of Hardie board or fiber-cement siding board capped by a piece of treated deck board covered with aluminum coil stock. It’s probably a lot of work to go through, but that’s my lot in life.
The last hurdle to accomplish was to carefully drill some holes in the sash, temporarily set the window in order to mark the holes to be drilled in the concrete rough opening, drill the holes, re-set the window, shim and level the window, secure the window with Tapcon screws and seal up the gaps with Great Stuff for Windows.
Now it’s starting to look like a window.

And here’s how both windows look before the finishing touches.

I’d love to tell you that this project was a real piece of cake, but it was very tedious and took significantly longer to complete than I planned. If I had to do it again, I’d suggest custom-ordering the windows to fit the opening to save on the hassle of having to grind the concrete. But as far as my projects go I was pretty satisfied overall.