Skinning over windows

[lornaschinske]

And then there's the places like what we went to... $260 shop labour plus another $200 for 17 pieces of 20 ga with one edge bent up at a 90* angle. We won't be doing that! Instead I have located a big roll of 24" X 50' heavy flashing for $66 at Ace Hardware here in town. David can cut it with his aviation shears and we won't need it bent anymore. We are keeping all the window frames and gluing the cut & painted flashing into the outer tracks of the window frames. Foamboard insulation and can foam for the "gaps" will be placed in the frames until level with the outer flange, then the whole wall will have a layer of foam insulation over all. My operating windows will be trimmed out with a trim not yet decided on... probably 1X3 PVC molding (PVC won't rot if the metal from the window trim condenses moisture).

[lornaschinske]

Will be glued/caulked in. We aren't worried about the metal pulling out. Aluminum does not shrink/expand THAT much. Our Alumimum skinned Eagle would grow 1" over a 40 ft span on a hot summer day.

[lornaschinske]

The aluminum sheeting will be glued to a substrate. Look, we built our food cart. It is aluminum sheeting glued onto a steel frame. No screws. No rivets. The substrate is blue foamboard. We have hauled the cart over 3K miles so far since we created it. It's been thru 2 NM summers as well. Nothing has worked loose (even when Stacey ran over an "alligator" in the road and the cart bounced a good 3 ft off the ground). This is a building method that we have used several times before and cannot see any reason why we shouldn't use it again. As far as the "size". We are keeping the original window frames and the aluminum sheets will be mounted in the actual aluminum framework. That means they will be cut about 27" wide (or what ever the width of the window is) by about 23.5" high.