How to Replace an Aluminum Front door Screen

Re-screening Tools

By Gary Boutin

Supplies and Tools:
Spline 11/64-inch
Fiberglass charcoal screening
Screen tool
1/4 inch screwdriver
Needle nose pliers
Scissors 
Razor knife 
Hammer

I received a call from Michael, from Uncommon Good, a program teaching students green energy. His home is located in Upland, California, a beautiful neighborhood with mature trees in a rural setting. He had just purchased a century-old home and wanted to preserve its look. Being a principal member of Uncommon Good, he was using the house to teach others how to go green. Instead of replacing the aging aluminum door, he decided to re-screen it.

This post shows the nine steps on how to replace the fiberglass screening on an aluminum screen door.

Step 1: Fig.1 shows the door has been removed, on the right side is the aluminum hinge with the pin inserted inside not to lose it. It is now ready for re-screening. Place the door on a clean dry surface, for example a cement driveway, to have a flat surface to work on., or use an asphalt driveway. The door must be placed screen towards the sky, and the metal decorations on the pavement, the channels must be in clear view to remove the spline from the screen channels.

Fig.1 Door pin

Step 2: Fig.2 and fig.3 shows the spline, that will catch the edges of the screen securing it into the metal channel. This job required the purchase of number .160 round or 11/64 inch spline package. The fiberglass screen comes in gray or charcoal and the size for this job was 36 by 84 inches. The package comes in a small bag and the spline in rolled in a circle. When you purchase the screen it will come in a 3-foot size roll. Now that the spline and screen has been purchased and the door is on a flat surface, use needle-nose pliers, or a 1/4 inch (6.35 millimeter) flat head screwdriver to remove the old spline.

Fig.2 Door and spline

Fig.3 Removing spline

Step 3: Once the tip of the spline is free, use the needle-nose pliers to pull the spline about 4-inches out of the metal channel. Then use your hands to pull the spline out of the metal channel freeing the old screen from the door. Remove the used spline and screen to the trash. Next, lay the new screen over the door, do not cut any of it, and get the new spline package.
Step 4: Fig.4 shows the spline is guided into the metal door channel with the screen underneath it. Next use the screen tool to roll the spline into the metal channel.

Fig.4 Screen tool

Step 5: Fig.5 shows as you move around the door to the metal handle, cut the screen around the handle. If you do not cut around the handle then the screen will not lay flat as the spline is pushed into the metal channel. Next when you do the other side, you must stretch the screen as you roll the spline into the channel. This is the process of getting a flat screen on the door. After the spline has been installed into the metal channel and you are satisfied that the screen is stretched flat and taut, then it's time to cut the excess screen off the door. Use the scissors to cut the bottom of the door screen, remove any excess.  

Fig.5 Door latch

Step 6: Fig.6 shows the use of a razor knife to cut the screen at the spline, not on the screen side, but on the metal side of the door.

Fig.6 Razor knife

Step 7: Fig.7 shows that the door has a new screen, the door needs to be rehung on the hinges. Use a hammer to hit the pins into the door hinges.

Fig.7 Hammer

Step 8: Fig.8 shows that after the door has been hung, re-install the door spring. The two screws need to be re-tightened because this spring helps the door re-close after it is opened.

Fig.8 Door spring

Step 9: Fig.9 shows the door re-screening is finished, and the screen keeps the bugs out. Looking at this post re-screening looks easy, but it can take up to 2 hours, but after a few screens the job does get faster.

Fig.9 Finished

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