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I am not a hack.
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Discussion Starter · #1 ·
I looked at a job earlier this week. First story walls are all brick. Pretty uncommon for california(cal/ore border zone). The old aluminum units appear to be set in mortar and obviously leaked like all hell.Replacing with vinyl units. No flange, no wood frame to nail to. Just an opening in a brick wall........on the coast, across the street from the beach in an area that gets 70" to 120" of rain and 70 mph gusts during the winter storms too:thumbsup:.

My thoughts were to use masonry screws through the side of the vinyl frame and a lot of Vulcom 116 caulking.
After the caulking dries, I would sac in a little mortar around the edge of the unit for aesthetic reasons.

Some have suggested installing some PT 2"x4"s around the brick opening (caulked of course)and using a smaller window unit with a flange. I still see weatherization issues between the lumber and the brick and the owner wants as much glass as he can get in there, any way. Besides the custom sizing would complicate the issue more and still doesn't guarantee against leaks.

The 2 units in the front are 8'0"-5"0"s.(4'0" center pane and two 2'0" sliders). The size of the unit also causes concern, especially in this application.Although they went with the thicker glass option, more window area+ high wind=more flexing and possible failure. I'm competing with a box store installer price. No bigee there. I don't want to have to keep coming back to PO'd owner everytime there is a storm.

Any of you "window masters" that specialize in lighthouses off the coast of Maine please kick down some knowledge.:notworthy:notworthy

Thanks.
 

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Sounds like a good job to let the other guy do.

Not sure I understand, the entire wall thickness is brick with a groove for the existing window flanges, or they are just fastened to the outside of the brick. Or there is an interior and exterior wall with the windows mounted to the interior wall under the brick?
 

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I am not a hack.
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Discussion Starter · #3 ·
All brick. No wood framing whatsoever. No flange. Existing windows appear to be mortared in. Very odd for this area and quite possibly one of the worst designs you can have on an oceanfront at the bottom edge of the pacific northwest. It might be one of those ones that will pay more NOT TO DO.
 

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Sounds pretty ugly. We did one like that, they had installation clips fastened with mortar in the center of the bricks, we attached the new windows to the clips and used the windows exterior accessory groove to fasten new trim from window to brick.

But this was in the middle of town, not on the ocean:laughing:.

Not sure what you could do that would be time/price efficient and still work.

Maybe double cap it, say bend a piece of metal 4" wide with a hemmed 1" lip. Lay this down on bottom, sides and top of jamb, caulked very well all around between metal and brick. Then put a large bead of caulk along the bottom of the lip and set your window up against it, inside of the metal.

After thats done caulk between window exterior and the outer edge of trim metal.

Then put on a second layer, either use 1x fastened to the brick and wrap, or the windows accessory groove to attach metal to.

If you used 1x's you could leave a little space between wood and window and cap the wood on 3 sides to get a 3/4" area of metal caulked tight to the window all around.

Don't know if that makes sense, all I can come up with on the spur of the moment:jester:.
 

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I did a couple windows in an old school building once that was brick and block where they mortared up to them on the outside and plastered the returns on the inside. The window fins set in a groove in the block
I just assumed I'd find lumber when I got the old window out but didn't. We messed up the plaster and the mortar getting them out. The contractor had ordered the windows two inches too narrow.
I had to furr the jambs out, wrapped the furr outs with metal, then re-plasterd on the inside and had a brick mason redo the mortar on the outside up to my metal.
Obviously, I got myself into a mess I wasn't expecting. I will spare you the details but I never did get paid for the job.
 

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I am not a hack.
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Discussion Starter · #6 · (Edited)
Bringin' her back up too the top.;)

The best game plan I've come up with so far:

1: Remove existing aluminum window.
2: Lay out exactly where new vinyl unit will sit in the opening.
3: Take a grinder with a diamond blade and cut a groove into the brick about a 1/2" deep around entire rough opening.
4: Install "z-bar" like piece of powdercoated aluminum flashing with a crapload of caulking underneath it. This piece will have two 1/2" bends in it. One bend will fit into the groove I cut into the brick. The other will bend up behind the window unit and be hidden by the interior trim.
5: Craploads of Vulcom 116 caulk.:gun_bandana:
6: Sac in a bead of mortar around window too cover huge beads of caulking for aesthetics.
Any opinions greatly appreciated.
 
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