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The project:
We originaly had installed cafe curtains to our patio on two sides, but the sunlight and weather caused them to go opaque and brittle, as we use this area quite a lot we wanted to replace them but not with more curtains. To replace them with something more permanent we decided to install walls with fly wire above and removable windows.
The walls are panels made to fit between the existing patio posts and have cement sheet cladding outside and shiplap linning inside, the windows are made from polycarbonate roofing panel cut to size and fitted in the window panels, on the outside of the window frames we fitted fly screen and trim.
We had to add an additional post on the end of the patio so we could fit in a door instaid off a full panel at that end.
There are four wall pannels in total and a clear oppening at the opposite end betwen the last panel and corner of the house.
- Materials:
Material List
90x45 framing pine
92x18 DAR pine
PPE flyscreen
Polycarbonate roofing panel
Cement sheet cladding
Wall lining
Foil insulation
(Ametalin 1350x10m Silver Wrap 0811067)
2.8x40mm Fibre cement nails
Staples for wrap & flyscreen.
General purpose polyurathane exterior sealant
Waterproof PVA glue
8 light external door
Hardwood door jamb set
Treated pine DAR post
WINDOW SASH LIFT T/MASTER NICKLE PLATE 17323
Pine skirting board.
Teated pine architraves
100mm Butt Hinges
Entrance lever lock set
All weather paint
Painters tape
- Tools:
Miter saw
Circular saw
Table saw
Drill driver
Air compressor
Air brad nail gun
Air stapler
Router
Hammer
Hand saw
- Step 1:
Design wall and window panels. Research available materials at Bunnings and make concept sketchs, measure openings to determine material quantities.
- Step 2:
Cut framing timber down so that the wall once assembled with the cement sheet panel and shiplap linning will be flush inside and out to the patio posts that are 98mm square. Pre fit silver wrap and fit the panel between the posts, note: use damp proof flashing to bottom of panel, fix to the posts using square head timber screws two per side.
- Step 3:
Cut and install cement sheet panel to outside of wall, caulk sides and bottom with polyurathane exterior sealant.
Fix shiplap linning to inside.
- Step 4:
Make and fit window framing. This is fixed with two screws per side and caulked on sides, top and bottom.
- Step 5:
Make window pannels to fit between the window frames allowing for clearance so they can be easily be removed, note: make the hieght of the panel 20mm shorter than the oppening.
The polycarbonate roofing is cut down with a circular saw to length and trimmed to width on a table saw to fit in grooves cut in the timber using a router or a table saw fitted with a dado blade, create a tounge on the styles then clamp and glue the assembled window panel together. The window panels could easily be constructed using rebates and trim to hold the poly carbonate in the frame.
Trim inside of each window frame with 25mm sq timber at the back to prevent the window panels falling out, fit a 25mm sq piece of timber at the top of the window frame spaced with around 3mm clearance for the thickness of the window panel.
Fit sash lift handles and barrel bolts to bottom of each window panel.
To remove the window panels lift and tilt out the bottom then pull down and out, installation is the opposite of the previous instruction.
- Step 6:
Install flyscreen to the outside of the window framing, using a staple gun fix one side and stretch to the other side using the roll of screen to grip before fixing all around with staples, this is a two person task. Cut off the rest of the roll. Fit trim over the stapled top, bottom, sides and middle then trim off rest of screen.
- Step 7:
We had to fit an additional post to the open end of the patio to enable the fitting of the end wall and installation of the door.
- Step 8:
Complete remaing wall and windows and hang door. Paint concrete floor before fitting door architrave and skirting. Caulk all joints and paint wall panels and trim to complete the project.
