DIY Double Insulated Glass || Save Money [How To] 

I am really impressed with all of the jigs, fixtures and tools you make in order for your projects come all together and dead on. You are always thinking the job all the way through.

These doors are turning out fantastic. Making these has been a learning experience for you and your viewers. Now you’re ready for mass production (lol).

Thanks. I researched this. Found only 2 or 3 vids on this subject. Your vid made it more DIY friendly

Definitely going to try this.

Pretty cool!

Excellent explanation!

Awesome process! It is looking so good!

Impressive, nice job!!

Thanks for sharing your knowledge! 👍👍👍👍👍 & Subscribed!!!

Great subject and video to go along with it, thanks for posting. Further paving the way for those of us who enjoy learning new skills and providing and doing for ourselves.

Very nice job as always looking very good!!!👍👌💯

Excellent. Very creative.

Interesting and well explained. Thanks for posting, and thumbs up.

Amazing job

Very nice video...Thanks for sharing your approach to the process...Well done!!!

I love that we are teaching each other how to do anything. Rock on.

I recall installing a huge set of double pane windows in a kit house ai helped build. The kit was created in Boston, then trucked to the mountains in Texas, so the windows could not be sealed, due to elevation change. At the top of each window, there was a small hole in the frame, with a thin copper tube, which was the argon fill spout, which we had to crush shut with pliers, then fill the hole with sealant. Anyways, I think if you ever did this again and wanted to fill your panes, you could get a small tank of welding argon from a welding supply shop, and do something similar.

This is an amazing video! Thank you I was going to put a saw curve in the outside edge of wood for the glass to sit in and space it apart and then seal it is a whole lot more efficient and better thank you

One of the most amazingly informative videos on RU-vid! Thanks so much! Can't wait to try this.

Awesome video! So informative! I've saved this for later use. Please use a riving knife and keep your fingers farther from the table saw blade. I had a kickback injury that probably would have taken two fingers if i didn't have a sawstop, instead i just needed 4 stitches. My hand was probably 4-6 inches from the blade making a rabbet when it happened.

I love your voice. I turned the voice speed down to 75% just so I could get the full tune and richness of your voice. I would like you to do a meditation video. Your voice is perfect for that genre. - - Tom I am currently located at, Latitude 35.24° North and Longitude: 97.47° West Height Elevation: 1182ft above sea level. -

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Cool. Nice work. I built a couple round windows for my step van rear doors out of plexiglass with double panes and get fogging between the panes in the winter. I separated the panes with 1/4 inch cork underlay. I don't quite understand how the moisture gets in there because I sealed with silicone where the external layer of plexiglass meets the aluminum of the door. Is it getting in from the inside of the door or outside? WHen I was making it I was wondering if I should also use silicone between the cork and 2nd interior layer of glass. Maybe I should have done that.

Great video! I can see where someone might be concerned about the windows fogging. Perhaps if you gave the interior a shot of dry gas, like CO2 or Argon before dropping the top pane on?

Coolness. I suppose if I wanted to make argon filled glass, I could use the same process, but then build a vacuum chamber box that I could attach a vacuum pump to, and some sort of tube with a ball inflation needle hooked to a cylinder of argon. Now my wheels are turning, and I'm going to be up all night dreaming about making windows.

Thanks for the video. This is exactly what I was looking for. I am trying to work up a cost estimate for my project. A few questions: 1) Did you use tempered glass? Where did you get your glass? 2) I see that the spacer comes in 66 ft lengths, so its pretty easy for me to figure out how much I need. Any idea how many ft you can get out of 1 tube of the sealant? How many tubes did you use in your french door project?

Anyone can buy argon but nitrogen works justvas well and should be slighty cheeper!

A small suggestion If one is concerned about a little fogging Why not put a small gel pack in a corner that they use in herbals? Do you think that might keep a lot of moisture out.

Great work

Great video! However, just wondering what happens to condensation, since you're not sucking any vacuum into the cell?

I think it would be very easy to install temporary tubes during your assembly process to pump in argon then seal the tube hole with sealant..?

Very cool! There's a product called Bloxygen which is just a spray can of argon gas. Its intended use is to spray some argon into partially emptied cans of paint or finish as you close the lid; it displaces the air so the paint doesn't skin over. I would think that one could use it to spray some argon between the sheets of glass before laying on the second sheet. Might work. 🤷

Omg this is epic! Instant sub, so glad the algorithm ended me up on this channel.

You are fearless. Great job. Have a good week.

Amazing job! Never knew this was possible as a diy

Can you add links to the products you used? Thanks!

So cool that you posted this vid, I have six 4'x6' casement units to make for my four season porch project. The money saved is enormous. Just the difference between material costs of 2019 and 2024 is sickening. Thank you so much, your tone and speed of speech is pleasant and easy to follow.

What an ingenious solution! That is so awesome. The doors look great - nice job!

Thank you, it looks easy for you, but this is always due to a massive amount of talent, you could make anything ! And you have a beautiful pair of hands.

@3:15 why did you use the table saw instead of the router? I've watched you do these types of cuts in lots of your videos (and your good at it) but it seems to me a router would be easier since you just send it through once and you're done.

Thanks Caitlin, you never fail to amaze. Love your templates for assembling these double paned glass units. You also covered my question about the moisture without my having to ask.

adding a hole on bottom and top and putting argon gas in there is not that hard. argon is available for welding and should go through a drying filter. as argon is heavy, the air escapes from top when you push in argon from bottom. when the gas coming out of the top hole starts disrupting a burning candle, you are putting out argon and you can seal the top hole, flip glass over, remove hose from "bottom" hole and quickly plug it as well and you have an argon filled double pane glass with far less chance of condensation.

Well you learn something every day, have never seen or even thought you could make you own double glazed units and with a couple of jigs the process seems fairly easy, could definitely get a bit messy but you can’t have it all, what a great video many thanks 👌👌👌👍👍👍🇦🇺

Yes, I'll go along with the "fearless..." cheers...rr Normandy, Fra.

Excellent work Caitlin, those doors are turning out magnificent¡¡¡, what a great job on the double glazing, excellent idea. A hug

Great instructions! For someone who plans on doing a lot of custom small panes you could setup a dehumidifier in one room and let it run several days before proceeding with the job. You can rent a cylinder of argon gas that we use for welding with a regulator. You will need two large veterinary hypodermic needles. One needle needs to connect with the gas output of the regulator while the second needle will be placed on the opposite side of the panel through the foam strip. WARNING! Please use a regulator set for its lowest possible setting and slowly purge the air out of the void. If you use too much pressure or without a regulator you will wind up with a glass bomb blowing up in your face! After a few minutes, turn off the gas supply and remove the supply needle and quickly apply a small dab of sealant to the first hole then quickly move to the second needle, remove it and seal that hole with a dab of sealant. Then proceed to fill the remains gap between the panes with the sealant. The larger the window the longer it will take to purge the air out of the pane.

Nice presentation. This should encourage a lot of diy couch sitters to attempt this. I would like to point out something that may be a problem however. If you use some kind of RTV sealant you can't guarantee it will keep out moisture. RTV cures from the moisture in the air and it must be permeable in order to cure all the way through. Anyone who has an old tube of the stuff probably had to toss it because there was a plug of cured material part way down from the cap, even though the cap was tight. A much better material would be butyl or polyurethane. However, the RTV might work better if you can argon fill. The argon is a big molecule and, unless there is a true leak, would likely keep moisture out fairly well. Another problem is that the whole glass assembly tends to "breath" because of temperature changes. Without a perfect seal, ie glass to glass, even argon would eventually be displaced. I had some steel doors that needed single Pane windows replaced with something better. I went through the whole process and determined that no seal material that I tried would moisture seal enough to prevent condensation, and no desiccant would last more than 2 or 3 seasons. However, when I filled with argon they were good for at least 5 years before fogging. These windows were on the north and south doors and the south would always fail first. All this work was an interesting personal experiment for me, another learning experience. Others would probably have different results. Always have fun.

Thanks for taking the time to make this video, this is something that I will be doing, in my part of Australia (Queensland) double glassing is not really used, but coming from the UK where it is a building code requirement I know the benefits. I want to use it to both keep the heat out during the hot summer months and for noise with us building near a road and railway line. I will have to see where I can buy that super spacer product here in Australia.

Thankyou Ma'am. My daughter has friends how started redoing an interesting little off grid house but material prices are driving them to a stop. My daughter has asked me to help them with a bunch of free labour. I'm 74 and retired so I am good to do a bit. I have a lift of 2 inch cedar and a good woodshop so here we go. We wanted to do a custom front door but costs said NO. With your idea for double glaze glass and the book by John Birchard the door idea they have should be something we can do. They thought glass chevrons with diamond shapes up the middle would be nice but that custom glass was a problem. Thankyou and God bless.

The double-paned glass will help with energy efficiency, but I expect it will also help the door to last longer: condensation running down into the frames will be a lot less, which will mean the wood will be drier on average than if you had used a single pane. The argon would only be a marginal and temporary improvement: still dry air is a really good insulator, and argon, nitrogen, and oxygen all diffuse through silicone pretty rapidly, so even the pro windows end up full of something very much like air in the long run.

was concerned about fogging til you mentioned the dessicant property in the foam sealer. looks like a good job and better idea. well done

Thanks for update. Would it be possible to draw a vacuum before completing the caulking?

Nice try, but that will fog up in under a year because you have moisture trapped inside.

You have achieved my ambition of making the insulated window product on a craftsman’s-craftswoman’s-scale. Great research, work and presentation. What about applying one of the reflective films available to one of the glass panels or even suspending a reflective film within the glass panels?

HB , nice job, yes D/G units are very expensive, wait until you go to triple glazed, I’ve only done two jobs like this, one was just three windows, But I made a lift and slide patio door , Cannot remember the precise size, but it took six of us to lift a unit unit into place, And if I remember rightly, the two units cost £1600, and this was about 16/7 years ago, and as you can imagine it was a very expensive job, When it came to the day to be paid, they started saying to me that there was cold air coming in from outside, Ha Ha , Obviously trying to either reduce payment or not paying me at all, I’ve had a few clients like this during the course of my working career, I asked my client to go and get a candle, which I lit and then went round the whole of the sliding door, unset to them if his air coming in, we will see the flame flicker, Four minutes later, I was being paid in full, Keep up with great work stay safe, I love the idea of making your own sealed units, I still have literally 102 m of rubber sealant to go round the internal and external or windows, And there is a special pair of scissors to use to cut the mitres on the joints on the ends, this past scissors cost £120 roughly, depending whether you are cutting internal joints or external joints is depending on how you use the scissors it has two razor blades inside of it , just cuts a notch-out .

Hi HB, I'm curious do you enjoy the versatility of the projects you take or do regret some? It seems you enjoy them, is that for the channel or do really enjoy them? I think you are able to do anything you set your mind to!!! Again another outstanding video! Timothy

Those prices are outrageous. Would be a couple of hundred of euro's at most here.

Thr process you showed is essentially how hardware stores fix customer windows that are doubled paned.

Strange use of a featherboard. Not safe and defeats the purpose, saw the profiles tilting while sawing...😮

Stop eating the microphone, then speak up. Enunciate, and project.

Great job Kat, love your ability to improvise.