Alexei Volkov
Creating window well covers out of corrugated plastic is a cost-effective and practical DIY project that can protect basement windows from debris, water, and pests while allowing natural light to enter. Corrugated plastic, also known as polycarbonate or fluted plastic, is lightweight, durable, and easy to work with, making it an ideal material for this purpose. By measuring your window well, cutting the plastic to size, and securing it with appropriate fasteners, you can craft a custom cover that fits snugly and withstands outdoor elements. This solution not only enhances the functionality of your window wells but also adds a clean, professional look to your home’s exterior.
| Characteristics | Values |
|---|---|
| Material Needed | Corrugated plastic sheets, utility knife, measuring tape, screws, washers, drill, sealant |
| Tools Required | Utility knife, measuring tape, drill, screwdriver |
| Steps | Measure window well, cut corrugated plastic to size, drill holes for screws, secure cover |
| Cost | Low-cost DIY project (depends on material size and quality) |
| Durability | Moderate (corrugated plastic is lightweight but may degrade over time with UV exposure) |
| Maintenance | Periodic cleaning and inspection for cracks or damage |
| Customization | Can be cut to fit any window well size or shape |
| Weather Resistance | Water-resistant but not fully waterproof; may require additional sealant |
| Installation Time | 1-2 hours per cover (depending on skill level) |
| Safety Feature | Provides protection against debris, rain, and snow while allowing light to pass through |
| Environmental Impact | Eco-friendly if using recycled corrugated plastic |
| Aesthetic Appeal | Simple and functional; can be painted or decorated for better appearance |
| Weight | Lightweight, easy to handle and install |
| Availability of Materials | Corrugated plastic sheets are widely available at hardware or home improvement stores |
| Longevity | Typically lasts 2-5 years depending on climate and maintenance |
| DIY Difficulty Level | Beginner to intermediate (basic cutting and drilling skills required) |
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What You'll Learn
- Materials Needed: Corrugated plastic sheets, tape measure, utility knife, screws, hinges, and weather-resistant sealant
- Measuring the Well: Accurately measure window well dimensions for a precise fit of the cover
- Cutting the Plastic: Use a utility knife to cut corrugated plastic to match well measurements
- Adding Hinges: Attach hinges for easy access and secure the cover to the well frame
- Sealing and Finishing: Apply weather-resistant sealant to edges to prevent water and debris entry
Materials Needed: Corrugated plastic sheets, tape measure, utility knife, screws, hinges, and weather-resistant sealant
Corrugated plastic sheets are the backbone of your window well cover project, offering durability, lightweight handling, and resistance to moisture. Choose sheets at least 4mm thick to ensure structural integrity without excessive flexibility. Opt for UV-resistant varieties to prevent degradation from sunlight, especially if your window well is exposed. Measure the dimensions of your well carefully, adding 2-3 inches to each side for overlap and secure attachment.
A tape measure and utility knife are your precision tools for this project. Use the tape measure to confirm the size of your corrugated plastic sheets before cutting, ensuring a snug fit over the window well. The utility knife, paired with a straightedge, allows for clean, accurate cuts. When trimming the plastic, apply steady pressure and replace the blade if it becomes dull to avoid jagged edges that could compromise the cover’s appearance or function.
Screws and hinges transform your flat plastic sheet into a functional cover. Select stainless steel or galvanized screws to prevent rust, especially in damp environments. Hinges should be weather-resistant and positioned along one edge of the cover for easy access. Pre-drill holes in the plastic to avoid cracking, and space screws evenly (every 6-8 inches) for maximum stability. Ensure the hinges allow the cover to open smoothly without binding.
Weather-resistant sealant is the unsung hero of this project, sealing gaps and preventing water infiltration. Apply a bead of sealant along the edges of the window well before securing the cover, and add a thin layer around screw heads and hinge joints. Allow the sealant to cure fully (typically 24-48 hours) before exposing the cover to the elements. This step ensures longevity and protects your basement from moisture damage.
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Measuring the Well: Accurately measure window well dimensions for a precise fit of the cover
Accurate measurements are the cornerstone of a well-fitted window well cover. Even a minor miscalculation can lead to gaps, instability, or an unsightly fit. Begin by gathering your tools: a tape measure, pencil, and paper. Measure the length, width, and depth of the well at multiple points to account for any irregularities. Note the highest and lowest points, especially if the well slopes or has a curved shape. These dimensions will dictate the size and shape of your corrugated plastic cover, ensuring it sits securely without obstructing the window or compromising drainage.
Consider the type of corrugated plastic you’ll use—typically 4mm to 6mm thick—and how it will bend or cut to fit the well. Measure the radius of any curves or corners to ensure the material conforms smoothly. If your well has a lip or edge, measure its height and width to determine if the cover should rest on it or extend beyond it. For wells with obstructions like drains or vents, measure their placement and size to incorporate cutouts in your design. Precision at this stage eliminates guesswork and reduces material waste.
A common mistake is neglecting to account for expansion or contraction of the plastic due to temperature changes. Add a 1-2 inch buffer to your measurements to accommodate this. For example, if your well measures 36 inches wide, cut the plastic to 37 or 38 inches. This ensures the cover remains functional in both hot and cold weather. Additionally, measure the clearance between the well’s top edge and the window frame to ensure the cover doesn’t interfere with the window’s operation.
Finally, double-check your measurements before cutting the corrugated plastic. Lay out the dimensions on the material using a straightedge and mark them clearly. If possible, create a template from cardboard or thin wood to test the fit in the well before committing to the final cut. This step-by-step approach guarantees a cover that not only fits perfectly but also enhances the functionality and appearance of your window well.
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Cutting the Plastic: Use a utility knife to cut corrugated plastic to match well measurements
A utility knife is your go-to tool for cutting corrugated plastic to size, but precision is key. Begin by measuring the window well dimensions twice to ensure accuracy. Mark the plastic sheet with a straightedge and a permanent marker, creating clear guidelines for your cuts. The corrugated structure of the plastic allows for easier cutting along the flutes, but resist the urge to rush—slow, deliberate strokes will yield cleaner edges. For curved or angled wells, consider using a flexible ruler or a compass to map out the shape before cutting.
The technique you use can make or break the final fit. Hold the utility knife at a slight angle, applying steady pressure as you follow the marked lines. For longer cuts, use a metal ruler as a guide to maintain a straight edge. If the plastic tends to crack or splinter, try scoring the surface multiple times before applying enough pressure to cut through. Practice on a scrap piece first to get a feel for the material and adjust your technique accordingly. Remember, corrugated plastic is forgiving but not indestructible—patience pays off.
Safety should never be an afterthought. Always cut away from your body and secure the plastic sheet firmly to your work surface with clamps or weights. Wear safety goggles to protect your eyes from flying debris, and consider gloves to prevent cuts from the knife or sharp plastic edges. Keep the knife blade sharp; a dull blade requires more force and increases the risk of slipping. If you’re working in a confined space, ensure proper ventilation to avoid inhaling plastic dust.
Once the plastic is cut, inspect the edges for rough spots or burrs. Use a fine-grit sandpaper or a deburring tool to smooth them out, ensuring a safer and more professional finish. If the cover needs additional shaping, such as notches for drainage pipes, measure carefully and cut incrementally to avoid removing too much material. Test the fit in the window well before finalizing any adjustments, as slight discrepancies can compromise the cover’s effectiveness. With careful cutting and attention to detail, your corrugated plastic cover will not only fit perfectly but also withstand the elements.
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Adding Hinges: Attach hinges for easy access and secure the cover to the well frame
Hinges transform a static window well cover into a functional, accessible solution. By allowing the cover to swing open, they eliminate the need for lifting or removing the entire structure, making basement window access safer and more convenient. This is particularly beneficial for emergency egress, routine maintenance, or simply ventilating the space.
Hinges should be selected based on the weight and size of your corrugated plastic cover. Standard butt hinges are a common choice, but consider heavy-duty options for larger covers. Ensure the hinges are made from corrosion-resistant materials like stainless steel to withstand outdoor conditions.
Attaching hinges requires precise measurement and careful drilling. Mark the hinge placement on both the cover and the well frame, ensuring alignment for smooth operation. Use screws appropriate for the hinge material and the corrugated plastic. Pre-drilling pilot holes is crucial to prevent cracking the plastic.
Secure the hinges tightly, but avoid over-tightening, which can damage the material.
While hinges offer undeniable convenience, consider potential drawbacks. Hinged covers may be more susceptible to snow and debris accumulation, requiring regular clearing. Additionally, hinges can create a slight gap, potentially allowing small animals or insects entry. Weigh these factors against the benefits of easy access when deciding if hinges are the right choice for your window well cover.
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Sealing and Finishing: Apply weather-resistant sealant to edges to prevent water and debris entry
Weather-resistant sealant is the unsung hero of window well covers made from corrugated plastic. Without it, even the most meticulously crafted cover becomes a sieve for water, leaves, and dirt, defeating its purpose. This step transforms a DIY project into a functional, long-lasting solution. Choose a silicone-based sealant designed for outdoor use, as it remains flexible under temperature fluctuations and resists cracking. Apply a generous bead along all edges where the plastic meets the foundation or frame, smoothing it with a caulking tool for a clean finish.
The devil is in the details when sealing corrugated plastic. Its ridged surface can trap air pockets, weakening the bond between the sealant and the material. To ensure adhesion, lightly sand the edges of the plastic to create a rough texture, then wipe away dust with a damp cloth. For added durability, consider applying a primer specifically formulated for plastics before sealing. This extra step enhances the sealant’s grip, reducing the risk of peeling or gaps over time.
While sealing is straightforward, timing matters. Apply the sealant on a dry day with moderate temperatures—ideally between 50°F and 80°F—to allow proper curing. Avoid rushing the process; follow the manufacturer’s instructions for drying time, typically 24 hours for initial set and 72 hours for full cure. Premature exposure to moisture can compromise the seal, leaving your window well vulnerable. Patience here pays off in longevity.
A well-sealed cover not only keeps out water and debris but also enhances safety. A tight seal prevents the cover from shifting or lifting in strong winds, reducing the risk of accidents. For added peace of mind, inspect the sealant annually and reapply as needed, especially after harsh winters or heavy rainfall. This small maintenance task ensures your DIY window well cover remains effective year after year.
Finally, consider aesthetics. While functionality is paramount, a neatly applied sealant improves the overall appearance of your project. Use a sealant color that matches or complements the corrugated plastic for a seamless look. With the right approach, sealing and finishing elevate your window well cover from makeshift to professional-grade, blending practicality with polish.
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Frequently asked questions
You will need corrugated plastic sheets (cut to size), a utility knife or saw, measuring tape, a straight edge, screws or rivets, and a drill. Optional materials include weatherstripping for a tighter seal and a clear plastic sheet for light transmission.
Measure the length and width of your window well, adding 2-3 inches to each side for overlap. Use a straight edge and utility knife or saw to cut the corrugated plastic to size. Ensure the edges are smooth to prevent injury and fit properly.
Yes, you can create a hinged cover by attaching hinges to one side of the corrugated plastic and securing it to the window well frame. Use screws or rivets for a sturdy connection. Add a latch or handle for easy access.
