How to fabricate custom aluminum flashing for a weather-tight window seal
In short: General contractor Tom Silva demonstrates the process of creating custom-fit aluminum Z-flashing. This video provides a practical guide for homeowners looking to protect their window installations from water damage using basic tools and a homemade bending jig.
Proper window flashing is essential for directing water away from the building envelope. The process involves using 8-inch-wide aluminum flashing, which is shaped into a Z-profile to fit over the window casing and trim. To achieve precise bends without a professional metal brake, Silva utilizes a homemade jig constructed from two beveled 2x8 boards and a 2x4 tapping block.
The fabrication process requires careful measurement and scoring. A framing square is used to mark straight lines, while a utility knife scores the aluminum before it is cut to length with aviation snips. A wood gauge block acts as a spacer to ensure the flashing accounts for the specific thickness of the window casing and trim, ensuring a snug, protective fit.
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Sources
- Summary by Intellect · source: How to Flash a Window | This Old House
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