How to replace a broken glass on an aluminum window

Written by rachelle proulx
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How to replace a broken glass on an aluminum window
Aluminium windows slide easily out of the window frame once you engage the release tabs. (Photodisc/Photodisc/Getty Images)

The glass in aluminium windows can break if something hits it or puts too much pressure on it. These windows have aluminium frames and are often called storm windows. You can find replacement glass for aluminium windows at home improvement centres and speciality window shops. Replacing the glass in an aluminium window can be a dangerous job because broken window glass is very sharp. Wear goggles and leather gloves at all times while attempting this project.

Skill level:

Things you need

  • Dust sheet
  • Mallet
  • Goggles
  • Leather gloves
  • Pliers
  • Rubber gasket
  • Measuring tape
  • Glass pane
  • Screwdriver
  • Utility knife
  • Scissors

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  1. 1

    Place a dust sheet below the window. Break the remaining glass out of the window with a mallet. Wear goggles and leather gloves as you hit the glass with the mallet. Pull out any stuck pieces of glass with pliers.

  2. 2

    Slide the window frame out of the window by aligning the sash hangers with the side channel notches. Push the release taps toward one another then pull the frame down and out of the window.

  3. 3

    Grab the rubber gasket around the frame with your hands or pliers to pull it up and out from around the frame. Set the rubber gasket aside.

  4. 4

    Calculate the size of the replacement glass by multiplying the rubber gasket's thickness by two and adding it to the length and the width of the inside measurements of the window frame.

  5. 5

    Locate the top corners of the frame. Slide the top of the frame up to reveal the L-shape brackets by unscrewing the corner screws that hold the top of the frame to the sides of the frame.

  6. 6

    Wrap the edges of the replacement glass with the rubber gasket. Reuse old gaskets if they are void of damages. Pull the gasket over the corners by cutting a small slit in the gasket where it meets the corner so the gasket will bend easier over the corner. Cut away the extra gasket when the glasses edges are wrapped.

  7. 7

    Slip the glass into the frame from the top of the frame. Line the edges of the glass into the channels in the sides and bottom of the frame. Line up the L-shaped brackets gently to connect the top and sides of the frame together. Set the top of the frame on top of the glass so the glass is completely framed with framing. Screw the corner screws back into place with a screwdriver to secure the frame around the glass.

  8. 8

    Insert the window back into the window opening. Align the sides of the frame with the window openings side channels. Push up on the window gently so it sides up and into the window opening. Push the release taps together to insert the bottom of the window into the window opening. The release tabs will separate to hold the window in place once aligned.

Tips and warnings

  • Do not attempt to remove a window that has broken glass still in it because the glass can fall out of the frame and cut you.

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