How to change flywire on aluminium sash window?

[happy57]

Hi there ...

window cornerbroken wirehold glassafter take out low window

We have the double hung sash aluminium windows, 1950's style with wire in the channel, the glass is not in frame, top and bottom use rubble casing and 2 pieces aluminium to be front and back with screws holding together, the glass left and right edge attached to the channel. We can't open the weight box, so we can't change the broken wire. Please see the attachment. 

Hope you can help. Thanking you,

[EricL]

Hello @happy57 

Welcome to the Bunnings Workshop community. It's sensational to have you join us and thanks for sharing your question about your sash window. 

If you are willing to explore and take a risk, I suspect that the aluminium cover at the front of the sash is actually a push fit cover. If you look at the last photo of your window, you'll see that there is a large flat piece of aluminium that sits right in front of the weight box. I suggest getting a sharp flat head screwdriver and inserting it in between the gap of the flat section and the channel body of the window and trying to lift it up. Once the cover is removed you should be able to access the weight box.     

However, if you are hesitant to damage the body of the window, I suggest engaging the services of an aluminium window specialist. They will have the knowledge and experience to disassemble your window.

If you need further assistance, please let us know.

Eric

[happy57]

Hi Eric,

Thank you very much for your reply.

You said " ... a large flat piece of aluminium .." it is I drawn black line part? please see the pic. If yes, we cut the paint and found it is a 90 degree and front inserting and right side outside, also can't lift it up. 

Thanking you, 

happy57black line piece?

[MitchellMc]

Given the age and style of your aluminium sash window @happy57, and the fact that it uses a proprietary weight and wire system, it can definitely be tricky to figure out how it all comes apart—especially if you’ve never tackled one before.

Unfortunately, we can’t give a definitive answer on how your specific model is assembled, but logically, there must be a way to access the weight box, even if it's not immediately obvious. It's likely that one of the components on that side—possibly the right-angle aluminium cover you've marked—is designed to be removed to allow servicing. If it's not budging, it may have been glued, caulked, or painted into place over the years.

You might need to go over each piece of the frame on that side, checking for even the slightest movement, or signs of fasteners hidden under paint. Look carefully for screw holes, clips, or tabs that could be holding it in. In some cases, the access point is a friction-fit cover or a section held in with sealant that needs to be carefully pried off or cut free.

If you can’t get anything to move and don’t want to risk damaging the frame, it might be worth getting a window repair specialist or glazier to take a look. They’ll be familiar with older systems and might be able to spot the access point quickly without dismantling things unnecessarily.

Please let me know if you have any questions.

Mitchell

[happy57]

Hi Mitchell,

Thank you very much for your reply. The marked left side is another small 90-degree piece and open between them I can see the weight. So, I have to take out the up sash window and then maybe the small 90-degree piece can go out, I can find more information. The big problem that many little parts are plastic made, no sure still on the market.

Thanking you,

happy57

[EricL]

Hello @happy57 

I suggest tyring to search for the spare parts first and see if you can find some. The good news is that should you fail to find parts; it is possible to reproduce them through 3D printing. If the parts are still intact and in one piece you can contact a 3D printing shop and ask them if they can reproduce the plastic parts for you. 

If you need further assistance, please let us know.

Eric