QUOTE(kelvyn @ Aug 7 2011, 05:00 PM)
If you are trying to reuse the grilles previously for window frames onto new aluminum windows, there is bound to be problems with the dimensions. Modifications are more labour intensive compared to totally new ones.
End of the day, if the modified grilles does not fit nicely onto the new window frame, who will be responsible? The grille make will not want to take responsibility and the owner will not accept.
Don't think there is any grill maker will take up such risk.
Most likely, they will propose that you make new ones.
They will take the exact measurements after the windows have been plastered.
my existing grille is 'connected' to the timber frame of the windows.
in theory, once i remove the grilles followed by the timber frames and windows, the aluminium contractor will install the outer frame. the outer frame should be somewhat smaller or even pre-agreed sizing. the contractor shall install the outer frame and let the masonry contractor do the touching up. this is to get even/straight levels and better finishing since outer frame will serve as a guide with proper leveling for the masonry contractor. and subsequently, the inner frame goes in and voila, windows exchange completed.
and lastly grilles to be reinstalled back to the original position but should now be hinged or connected to the masonry area. if dimensions goes wrong, can weld a 'ear' to the grille for hinging onto the wall surface as well. it's not difficult but needs some effort and coordination. but somehow senses contractors would not be so generous to offer their extra effort to do so for me.
my biggest concern rather would be whether the making good or touching up to the removed timber frames would be make good using proper material such as grout rather than plaster to prevent shrinkage and cracks appearing after the installation of the windows. and whether there's sufficient strength in the making good to 'receive' the grilles after.
sigh!