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LeeMn
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# Posted: 30 Nov 2024 11:23pm
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Very substantial. They look nice.
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toyota_mdt_tech
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# Posted: 1 Dec 2024 12:28pm - Edited by: toyota_mdt_tech
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Thanks ICC, coming from a fellow metal fab guy means a lot. I been thinking on this design for a long time, wanted it simple, wanted it easy to mass produce, didnt want all differnt types of metal or any mitered cuts and when I came upon the barrel hinges, the light went off. I thought of bars but this is better to protect from branches etc. The expanded metal was $100 for 4X8 sheet, I will need to pick up one more sheet to finish the final 2 windows, frames all done, just add the mesh and paint.
After I got the mesh on, the angle iron cover did shrink or curl a tiny bit, so barrel hinges at the top didnt align. I did drill out cup end of hinges 1/16" larger and counter bored or chamfered the opening for easy indexing, but in the end, I had to cut off one barrel cup and reweld it in its new shape. Small 5 minute set back, but didnt think the angle iron would curl. I have tried welding a few on one side, move to the next, then top and bottom to keep heat to a minimum, no help.
I have allowed 1/4" gap all around the window probably drill some small drain holes to allow water to drain out the bottom.
Here is a few I have completed including paint.
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toyota_mdt_tech
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# Posted: 6 Dec 2024 08:12am
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OK, all done except the mesh for the last 2 windows, picking up a 4X8 sheet of the expanded metal this Saturday AM at the metal supply store, then to glue it in place (weld), then paint job, then load and strap down into trailer for spring run.
On to next project. 
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toyota_mdt_tech
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# Posted: 8 Dec 2024 07:05pm
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Mesh for the last 2 windows are cut and glued (welded) in place and painted. All 6 window covers done. Closed issue. Next photos will be of them installed on the cabin in spring.
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ICC
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# Posted: 8 Dec 2024 10:23pm
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CharlieMichael
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# Posted: 22 Nov 2025 04:31am
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Quoting: LeeMn I am gutting our 1970's hunting cabin in northern WI. We have it down to the studs and replacing windows soon. it is right on a dirt road and ATV/snowmobile route. Frequent traffic. We have owned it since 2020 and was broken into many times over the years. Our shed was broken into this Feb. There is no electricity within miles of cabin. Right now we have plywood sheets on hinges on outside of cabin that have toggle bolts through the window frame and secured with wingnuts on inside of cabin. Looking for better design for preventing people from breaking in. Any ideas?
Consider removable steel/security bars or reinforced polycarbonate panels for the windows. Add solar-powered motion lights or alarms to deter break-ins—layering physical barriers with visibility works best.
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toyota_mdt_tech
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# Posted: 22 Nov 2025 11:58am - Edited by: toyota_mdt_tech
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Just realized I post pictures of them all installed.
I found they look so nice, I dont even remove them when I am there except one for emergency egress.
When a window is open, doesn't impede air flow or really obstruct view being in black.
I have added 4 retainers, 2 on the top, 2 on the bottom, this is to allow me to slide in a chunk of that white cement board you put under tile floors. They slide right in, slide out when there, good fire protection also.
While I was doing these installs, I also installed a steel mesh screen over the gable vents to stop blowing embers. It did have a nice nylon screen for small bugs, but needed more.
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