DIY Foldable Fly Screen for New Build Windows

This guide details how to construct a custom, foldable fly screen for new build windows, particularly useful for rooms that tend to overheat and require open windows for ventilation. The goal is to prevent insects from entering while allowing fresh air in.

Project Overview

The fly screen is designed to fit a specific window opening, typically a large, horizontally divided window without a central dividing bar. It is constructed from a frame that holds a fiberglass mesh, secured in place by magnetic strips. The design allows for easy insertion and removal.

Required Materials

• 8 x 1-meter white square PVC pipes
• 4 x 10 cm white corner connectors (3D printed)
• 4 x 10 cm white connecting pins (3D printed)
• 1 x black fiberglass fly screen mesh (approx. 140 x 150 cm roll)
• 1 x tube of white assembly adhesive
• 1 x tube of gel super glue
• 10 mm wide, 5 m long double-sided tape
• 10 mm wide, 5 m long self-adhesive metal tape
• 10 mm wide, 5 m long self-adhesive neodymium magnetic tape

Required Tools

• Old vegetable knife with a smooth blade
• Fine rasp (for deburring pipe edges)
• Scissors
• Cutter or utility knife
• Wire cutters
• Tape measure
• Pencil
• Protractor

Construction Steps

Frame Assembly

1. Prepare PVC Pipes: Cut the 1-meter PVC pipes to the precise measurements required for the window opening. Since the window is large, the pipes will need to be joined. Using the 3D-printed connecting pins and corner connectors, assemble the pipes into two vertical frame halves. Ensure the corners are square using a protractor. The connecting pins allow for slight adjustability before the adhesive fully cures.
2. Create Soft Hinges: Connect the two assembled frame halves using strips of thick, transparent PVC foil. Secure these strips with gel super glue to create flexible hinges, allowing the frame to fold. These hinges are reinforced by the subsequent application of double-sided tape and magnetic tape.

Attaching the Mesh and Magnets

1. Apply Double-Sided Tape: Apply 10 mm double-sided tape along the entire inner edge of both frame halves.
2. Mount Fly Screen Mesh: Lay the black fiberglass mesh over the taped frame, ensuring sufficient overlap. Press it firmly onto the tape. Stretch the mesh slightly to prevent sagging.
3. Attach Magnetic Tape: Apply the 10 mm neodymium magnetic tape along the outer edge of the frame, over the mesh. This tape can be cut to size after application.

Reinforcing the Frame

1. Trim Mesh: Use a cutter to trim the excess fly screen mesh from the outer edges of the frame.
2. Add Reinforcement: Glue short pieces of the remaining PVC pipe onto the inner side of the vertical frame joints for added stability. These pieces also serve as handles for inserting and removing the screen.
3. Corner Bracing: For extra rigidity, glue large transparent plastic triangles (cardboard thickness) into the four corners of the frame to support the 3D-printed corner connectors.

Preparing the Window Frame

1. Apply Metal Tape: Clean the inner rebate of the window frame thoroughly. Apply the self-adhesive metal tape along all four sides of the window rebate. This metal strip will act as the counterpart for the magnetic tape on the fly screen frame.
   • Note: The metal tape is thin and can be cut with wire cutters. It is designed to be unobtrusive and not hinder window closure.

Installing the Fly Screen

1. Insert the Frame: Carefully insert the completed, foldable fly screen frame into the open window. The magnetic strips on the frame should securely attach to the metal tape applied to the window rebate, creating a strong seal. The magnets provide significant holding power, preventing the screen from being dislodged by drafts.

This DIY project provides an effective and customizable solution for keeping insects out of newly built homes while allowing for natural ventilation.