SCREEN/STORM PANELS Storm and screen panels can be purchased cheaply enough that it’s not worth your time to make them yourself. Plan to pay about $45 for the screen panel. The storm panel costs more, because building codes require that it be made from tempered or safety glass. Once our doors are built they’re routed to create a rabbet that accepts a recessed screen/storm panel. We used custom-built screens and dead-light panels with aluminum frames purchased from a company called Harvey Industries. These panels will insert into the rabbet and fit flush to the doors’ faces.
The screens are available with fiberglass insect window screen, aluminum insect screen, solar insect screen, or 20x30 mesh no- see-um window screen for protec- tion from tiny insects, as well as pet-resistant screen material. The aluminum frame size options include 5/16-, 3/8- or 7/16-in. thick by 3/4-in. wide. Frame color choices are white, bronze, silver, tan and cham- pagne. A variety of attachment hardware is available to meet most applications. We prefer using the 7/16x1-in. HD window screen and a storm panel frame made of heavy .025 mill thick, roll-formed aluminum. It is cambered (slightly bowed) to retain screen tension when installed. To secure the frames in the door rabbet, we use turn clips or Marvin Window turn buttons and stainless steel screws for attachment.
For this project, we used a high- performance wood called Accoya which has been modified by a process called acetylation for exceptional dimensional stability, durability, and paint retention in outdoor environments.
Select the straightest, best quality boards you can find for this project.