Find something weather-resistant so the UV-radiation doesn't destroy it immediately. I was surprised at how much some of these materials cost. That area should match the cross-sectional area of the groove. The O-ring should be chosen based on it's cross-sectional area. You should find the O-ring and let that determine the width of the groove. The O-ring groove is 1/8", which is a poor choice because there were no available O-rings with the appropriate diameter. I designed my frame to accommodate 1/8" glass and 3/8" trim. Note that the thermal performance of this window sash is improved by not using a metal spacer between the layers of glass. The air gap is created by using the wood of the sash. It acts as the spacer between the sheets of glass it provides a place for the O-rings that seal the glass to the frame it provides a place to add trim, which holds the glass in place and it provides a structure that supports the glass. The sash of the window is the trick to this design. Please remember to rate this instructable by clicking on the little stars on the right! Air-filled windows have the advantage that a normal person can replace glass and replenish desiccant without any special equipment. However, I think that most older windows have long since lost whatever special gas filling they may have once had. Other gases may lower the convective losses due to higher mass, which leads to slower diffusion. One often-mentioned disadvantage of an air-gap (instead of noble-gas filled) double-glazed window is the convective loss due to air circulating around in between the sheets of glass. If it begins to collect moisture, the seals can be replaced and new desiccant can be added. If someone breaks the glass, it can be replaced with readily available glass sheets from a home-supply store. It can be built and maintained by a person of modest skill and at minimal cost. The design shown below is a true DIY double-glazed window. Most double-glazed windows are only expected to last 10 years in moderate climates, and less where there are temperature extremes due to the seasons, which is reason enough to be able to maintain a window. For example, if a double-glazed window is broken, replacing it may be very difficult and expensive due to custom sizes, discontinued models, and companies going out of business. Although this is a good design to reduce the cost and complexity of manufacture, there are drawbacks. Double-glazed windows are usually made from pre-fabricated glass panels.
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