Easy DIY AC Screen with Zip Ties

Make an easy DIY AC screen with lattice and zip ties…

There are many AC screen tutorials. A lot of them require posts and concrete, etc. And although that would make for a super sturdy solution, we wanted to build something more temporary, and easier to move.

We are going to be doing some construction near the AC pad outside the house in the near future, so we knew this AC screen may not be a forever installation.

And because we were aiming for temporary, moveable, quick, and easy, that seemed to be screaming for none other than ZIP TIES!

Here’s what we’ll cover in this DIY tutorial:

We love a good project that uses nylon cable ties. Instead of hinges, we put this sucker together with zip ties.

But if you did want something a bit more permanent or professional-looking, you could easily substitute the cable ties for hinges, L-brackets, or opt to simply screw the sides of your AC screen together.

Here’s a video of the construction of our DIY ac screen for you…

How to construct your AC screen:

1. Determine​ ​the​ ​size​ ​of the screen you need. 

The screen will be comprised of 2+ (in our case, square) sides. Depending on your setup/situation ​​you​ ​may​ ​be able​ ​to​ ​get​ ​away​ ​with​ a​ ​2-sided​ ​screen​ ​vs​ ​a​ ​3 or 4-sided​ ​screen.​ ​​

We​ ​opted​ ​to​ ​go​ ​with​ ​a​ ​3-sided screen,​ ​with each square measuring​ ​43”x43”.

You​ ​should​ ​leave​ ​a​ ​minimum​ ​of​ ​12”​ ​between ​the​ ​screen​ ​to your​ ​condensing​ ​unit​ ​(this​ ​is​ ​the​ ​technical​ ​name​ ​for​ ​the​ ​outside​ ​part​ ​of​ ​your​ ​home​ ​air conditioning​ ​system).​ ​​

Even​ ​though​ ​the​ ​screen​ ​we​ ​are​ ​building​ ​is​ made​ ​of​ ​lattice,​ it​ ​is​ ​still​ ​smart​to​ ​maintain​ ​this​ ​12”​ ​distance​ ​to​ ​maintain​ ​good​ ​airflow​ ​around​ ​the​ ​unit.

2. Route​ ​a​ ​groove​ ​in​ ​the​ ​2×2’s.​ ​​

The​ ​size​ ​of​ ​the​ ​groove​ on the frame ​is​ ​3/4” x 3/4”​ for each piece of lattice used. If you plan to double up your lattice, then make the groove 1″ x 1″.

Use ​the table​ ​saw​ ​to​ ​make​ ​this​ ​groove.​ ​​ Set​ ​the​ ​depth​ ​of​ ​the​ ​saw​ ​at​ 3/4”​ ​and​ ​run​ ​the​ ​2×2​ ​through​ ​the saw​ ​a​ ​bunch​ ​of​ ​times​ ​to​ ​cut​ ​this​ ​groove.​

You​ ​won’t​ ​be​ ​able​ ​to​ ​remove​ ​all​ ​the​ ​material​ ​using​ ​the table​ ​saw,​ ​but​ ​you​ ​will​ ​be​ ​left​ ​with​ ​a​ ​few​ ​thin​ ​pieces​ ​of​ ​wood​ ​that​ ​you​ ​can​ ​easily​ ​break​ ​off.​

​Once we​ ​broke​ ​off​ ​what​ ​we​ ​could,​ ​we​ ​used​ ​a​ ​chisel​ ​(make​ ​sure​ ​it​ ​is​ ​sharp)​ ​to​ ​remove​ ​the​ ​rest​ ​of​ ​the material.​ Repeat​ ​this​ ​for​ ​the​ ​second​ ​2×2.

3. Cut 45-degree angles on the 2×2 frames.

To fit together like a frame, cut​ ​(4) of the​ ​2×2​ ​pieces​ ​to​ ​length​ ​using​ ​the​ ​miter​ ​saw​ ​set​ ​at​ ​a​ ​45-degree​ ​angle.​ ​Once cut,  ​they​ ​should​ ​fit​ ​together​ ​like​ ​a​ ​picture​ ​frame.

4. Dry fit frame pieces.

Lay​ ​the​ ​2×2​ ​pieces​ ​out​ ​on​ ​a​ ​flat​ ​surface.​ ​​Don’t​ ​screw​ ​them​ ​together​ ​just​ ​yet.​ ​​Once​ ​you​ ​have​ ​the 2×2​ ​laid​ ​out​ ​and​ ​dry fit,​ ​measure​ ​the​ ​distance​ ​from​ ​groove​ ​to​ ​groove.​ ​​

Now​ ​subtract​ ​1/4”​ ​(a​ ​1/8” for​ ​each​ ​side)​ ​and​ ​this​ ​is​ ​the​ ​size​ ​of​ ​the​ ​piece​ ​of​ ​lattice.​ ​​​We​ ​subtracted​ ​the​ ​1/4”​ ​to​ ​ensure​ ​the lattice​ ​fit​ ​down​ ​into​ ​the​ ​groove.

5. Cut​ ​lattice.​ ​​

You​ ​will​ ​cut​ ​the​ ​lattice​ as ​you​ ​would​ ​a​ ​piece​ ​of​ ​plywood.​ Once you​ ​have​ ​marked​ ​the​ ​size,​ ​use​ ​the​ ​circular​ ​saw​ ​to​ ​make​ ​the​ ​required​ ​cuts.​

Important​ ​tip​ ​here, make​ ​the​ ​first​ ​cut​ ​where​ ​you​ ​basically​ ​cut​ ​the​ ​lattice​ ​in​ ​half,​ ​don’t​ ​make​ ​the​ ​long​ ​cut​ ​on​ ​the​ ​8’side​ ​first​ ​as​ ​you​ ​will​ ​need​ ​this​ ​larger​ ​piece​ ​of​ ​lattice​ ​for​ ​Step​ ​7.

6. Assemble​ ​the​ ​ AC screen.​ ​​

Place​ ​the​ ​lattice​ ​inside​ ​the​ ​groove​ ​of​ ​the​ ​2×2’s.​ ​​It’s a good idea to pre-drill holes ahead of screwing the frame together to prevent cracking your wood frame. ​ ​

With the lattice seated in the groove, screw the​ ​2×2’s​ ​together​ ​using​ ​the​ ​2.5”​ ​screws,​ ​one​ ​at​ ​each​ ​corner.​ ​​​

We placed the lattice into the groove before screwing the frame​ together​ ​to​ ​ensure we​ ​had​ ​a​ ​snug​ ​fit.​ ​

Using​ ​the​ ​staple gun to attach the​ ​lattice​ ​to​ ​the​ ​2×2​ ​frame.​ ​​The​ ​staple​ ​size​ ​will​ ​vary​ ​based​ ​on​ ​if​ ​you​ ​are​ ​going through​ ​a​ ​single​ ​piece​ ​of​ ​wood​ ​or​ ​two​ ​pieces​ ​of​ ​wood​ ​(lattice​ ​is​ ​made​ ​up​ ​of​ ​crisscrossing​ ​pieces of wood, so you might end up with a single layer or a double layer at the groove, hence the need for different size staples).

7. Attach an additional layer of lattice, if desired.

For some screens, this single layer of lattice would be enough, but when we placed a single layer of lattice in front of our air conditioning condenser, here’s what we saw…

It didn’t seem to be cutting the mustard if the goal was to make a true screen. We decided to add a second layer of lattice.

Place the screen you just built face down on a flat surface. Take the remaining lattice from Step 5 and place it over the ac screen.

Adjust the lattice so you the have look you want. Now mark the lattice and cut it to size. Place this second piece of lattice back on top of the screen and use the stapler to attach it to the screen.

Again, depending on the layout of the lattice, you will need different size staples to attach it. It’s best to determine how many layers of lattice you’ll need BEFORE assembling the frame.

For more than 1-layer of lattice, the channel routed in your frame needs to be 1″ instead of 3/4″ as we discussed at the beginning of the tutorial.

8. Repeat above for additional sides of the screen.

Great work, you have one square section of your ac screen complete! Now you’ll repeat these steps to get each additional desired section of your screen built.

9. Install ac screen around condensing unit.

Once you have all the screens built, place them around your condensing unit (maintaining that 12” clearance). We attached our screen sections together using nylon cable ties.

This allowed for an easy installation and minor adjustments to be made.

You could also use hinges, L-brackets, or just screw the screens together once you have them in place if you prefer.

Pin this DIY ac screen project for later! And if you make one, leave a comment (or better yet, a photo) on the pin! That helps others know whether they want to try this project, too!

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