https://github.com/hriodyahmed/code/wiki/How-to-Replace-Aluminum-Windows-with-Vinyl

The question on how to replace aluminum windows with vinyl has been raised several times in home improvement forums. Today I present my answer on how to do it best.

One thing I must first emphasize is that there is no one best way to do it. In addition, there are a lot of issues that affect the manner in which you should do it – as compared to someone else. For example, the style of the house, is it a stucco house, the age, the frames, glazing, and more.

Let me say this before I forget – you will definitely need a helper. He or she will be able to help set the bottom of the vinyl window onto the aluminum bottom track and also help raise it into position. Basically a helper will be useful in keeping everything into place while you take care of the rest.

If the window is a retrofit then it should come with an extra interior that has trim. In this case, drill holes that are 3/9 inches in the areas of the frame where you want to screw it in. Usually, there are 3 holes on the top and on the sides.

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Then remove the old panels and add a heavy bead of caulk on the face of the old aluminum. You will then need your helper to set the bottom of the new window on to the old aluminum bottom track and then raise it into position.

Now let the helper hold it while you go inside to center the window into the opening. You should slide the vent panel open and then shim the bottom or left corner to adjust for out of square conditions. You can shim by placing a shimming material between the sills and the bottom of the frame.

Once you get it to be square drive a three-inch deck screw through the holes drilled earlier leading into the wood studs. Make sure you don’t tighten too much. After inserting the crews into the top and sides then remove the sliding panel.