How to build Good Looking Interior Window Insulation Panels

My design is an adaptation of Art Tec - Guy Marsden’s great tutorial of Building Interior Window Insulation Panels.  Please thoroughly read his tutorial, as it is far more detailed than mine.  My modifications also require greater carpentry skills and more than just basic hand tools.  You should plan ahead as it took me five weeks to complete the 13 panels my house required.  I finished mine just as Spring time arrived!  This is better suited for a Summer or Fall project.  I made one for the attic access panel too.

List of Supplies Needed:

• 1x4” Pine Boards
• 2 1/2 and 3” drywall or deck screws
• Screen Spine
• I purchased 1000 ft of .140” gray screen spline from Blaine Window Hardware Inc.  (.120” spline was too loose fitting and .125 from Home Depot was just about right, but too expensive.).  It needs to be stretched out just before installing.
• Frost King / Thermwell 4’ roll Crystal Clear Vinyl Sheeting from Home Depot, but can be found in larger roll sizes one the web.
• This vinyl sheeting has a odor to it when new (caused by outgassing).  After completing the panels, I had to leave them in the basement for a week or two until the odor went away.
• 1/2” x 3/4” wide Foam Tape.  I used  gray open cell urethane foam Ester type for better UV resistance.  Measure your window frames very accurately, because this foam does not compress as easily as the Ether type.  (The window panels are still easily installed).  I purchased it from foamtapes.net.

List of Tools Needed:

• Table saw with a 1/8” wide blade
• Power Miter Saw
• Router Table with a 3/16” round over bit
• Screen Spline Tool
• Drill with a long bit and a countersink
• Glue Gun
• Scissors
• Utility Knife
• Corner Clamp
• Screw Drivers

Construction Tips:

• Measure EACH window frame as accurately as possible.  Measure at different points along the frame to get the average height and width of the frame.  Subtract 1/2” from the measurements to get the insulated panel dimensions. 

Insulated Window Panel Construction Photo Gallery