How to Board Up Windows Using Plywood in 6 Steps

 Feel like a DIY genius with this essential and straightforward project

Carpenter cutting a piece of plywood with a circular saw
Photo: The Good Brigade / DigitalVision / Getty Images
Carpenter cutting a piece of plywood with a circular saw
Photo: The Good Brigade / DigitalVision / Getty Images
SKILL LEVEL
Simple
COMPLETION TIME
2 hours
COST
$100–$400
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What you'll need:
TOOLS
  • Measuring tape
  • Circular saw
  • Hand saw (optional)
  • Drill
  • Screws
SUPPLIES
  • Plywood boards
  • Industrial-grade hook and loop fastener strips
  • Sandpaper
  • Barrel bolts
  • Two-inch lag screws

Ensuring the safety and security of your home is a top priority, particularly in the face of storms or intruders. Boarding up windows is a practical and effective measure to achieve that goal. But the trick to safeguarding your home successfully is learning how to board up windows based on your unique home type. We share techniques for wood, vinyl, stucco, concrete, stone, and brick exteriors. Let’s get cracking.

Prepping to Board Up Windows  

Boarding up windows with plywood differs based on your home type.

Vinyl, Concrete, Stone, and Stucco Exteriors

These typically need industrial-grade adhesive-backed hook and loop fastener strips (one popular brand is VELCRO®). You can attach these strips to the plywood boards and align them with the corresponding strips on the window frame, providing a secure and temporary attachment without damaging surfaces. 

Wood Exteriors

With wood, you may want to take a more robust approach. You can drill pilot holes into the wood frame and then use screws to secure the plywood.

Brick Exteriors

Barrel bolts are often employed for brick exteriors and must be drilled directly into the masonry. This requires a careful and steady hand, and it may be a task better suited for a professional if it’s something you’re unsure about.

Costs and Expenses

The average cost of boarding windows with plywood is around $250, with fees ranging from $100 to $400 per window, depending on whether you DIY or hire a pro. If you hire a professional window installer near you, labor costs can hover between $50 to $100 per hour

According to recommendations from insurance industry groups, you should use plywood that is at least 5/8-inch thick and of exterior-grade (CDX) quality. A 4-by-8-foot board that you can cut to size starts at $55. Another expense is adhesive-backed hook and loop fastener strips, which will add $4 to $20 to your project’s budget.

How Much Wood to Buy

To determine how much plywood you need, measure the height and width of the window opening and tack on an additional 2 to 4 inches on each side, depending on your type of home exterior. More on that shortly. If you plan to secure the plywood with tape, you won’t need extra material. Size the board to cover the window frame completely.

  1. Measure Your Windows

    Measuring windows is a precise job. Follow these guidelines to ensure your plywood board is cut to the right size for maximum window protection. 

    For Wood

    Add 8 inches to the width and height measurements for wood exteriors, allowing the boards to create a 4-inch overlap on both sides of the window. However, if the window sill extends beyond the trim, add only 4 inches to the height measurement. Afterward, use a pencil and your measuring tape to mark the cutting lines accordingly.

    For Masonry or Brick 

    For masonry or brick houses, measure the width and height of the inset on the exterior designed explicitly for each window. The inset should have a depth of at least 2 inches. Now you’re ready to transfer your measurements to the board.

    For Vinyl, Concrete, Stucco, or Stone

    When dealing with vinyl, concrete, stucco, or stone siding, use a tape measure to determine the height and width of the window, including its framing but excluding the surrounding trim or structural frame. If the window has an extended bottom sill that protrudes further than the rest of the window, measure the height from the top of the sill. Add 8 inches to the height and width measurements, and mark the cutting lines accordingly. 

    Now you can use a pencil to draw your lines for cutting the plywood.

  2. Cutting the Plywood

    Female carpenter using saw for cutting plywood
    Photo: Amorn Suriyan / Getty Images

    Use a hand saw or circular saw to cut plywood panels to the dimensions you marked on the board. Wear safety gloves and eye protection. When you’re ready to get sawing, cut slightly outside the lines to account for the thickness of the saw blade. 

  3. Smooth and Finish the Boards

    After you cut the plywood, inspect the edges. If there are any rough or splintered areas, use sandpaper to smooth them out. It will help ensure a safer and more secure installation. 

    If you plan to use these boards again, apply a weather-resistant wood sealant at this time to preserve the wood's longevity. It can take up to 48 hours for the sealant to cure.

    If you are boarding up multiple windows in different sizes, assign a unique number to each plywood panel to indicate the corresponding window it will cover. Additionally, if you have unique-shaped windows, mark an arrow on each board to indicate the correct orientation, showing which end should be positioned upwards. These steps will help to ensure your project goes as quickly and smoothly as possible.

  4. Securing Boards to Wood Exteriors

    Man attaching plywood to cover a window
    Photo: kurgu128 / Adobe Stock

    You will want to drill pilot holes through the plywood for wood exteriors, ensuring they align with the wooden frame beneath. This step helps prevent the wood from splitting when inserting screws. When undertaking this task, select a drill bit that’s slightly smaller than the screws you intend to use for a secure fit.

    Make sure to evenly space your pilot holes (around 3 to 4 inches apart is a safe bet) around the board to provide adequate support and prevent the plywood from sagging or becoming dislodged. 

    Now grab a buddy and have them hold the board over the window. Then pick up your drill. Insert your first lag screw and then a washer through the pilot hole, attaching the plywood firmly to the wooden frame. Repeat the process until you are finished.

  5. Securing Boards to Vinyl, Stucco, Stone, and Concrete Exteriors

    Boarded up windows with plywood storm shutters for hurricane protection of residential house
    Photo: Bilanol / Getty Images

    It is essential to avoid damaging your home's exterior while achieving a reliable attachment. Instead of drilling holes directly into your home, use industrial-grade adhesive-backed hook and loop fastener strips. 

    Attach these strips along the edges of the plywood and align them with corresponding strips or tape on the window frame. This method provides a secure hold without the need for drilling or screws, minimizing potential damage to all types of surfaces.

  6. Securing Boards to Brick Exteriors

    When preparing holes for these types of exteriors, you'll need to account for the sturdy nature of the material. It will involve a more systematic approach so you don't harm the grout between the bricks.

    Mark the spots for the barrel bolt holes on the plywood and the brick or stone. You want to ensure that you are drilling into the brick, not the grout. Now drill your pilot holes in the plywood board. Afterward, install a masonry drill bit and do the same on the brick.

    Next, have your buddy help hold the board over the window. Insert the barrel bolts through the plywood and into the pilot holes in the brick. Finally, fasten the barrel bolts tightly to secure the plywood board, providing a robust barrier against external elements.

Frequently Asked Questions

You can choose 5/8-inch plywood or 3/4-inch plywood—anything thinner than these sizes may not withstand the impact of debris propelled by strong winds or can be easily torn off by intruders. Remember that the durability of the wood board is crucial, particularly for safeguarding your windows during severe storms. The effectiveness of using wood boards for protecting the investment you made in your home relies on using the appropriate material and ensuring proper installation.

All wood boards can warp, but thicker plywood offers a notable advantage in terms of reduced warping. The additional thickness increases stability and strength, making it less prone to warping than thinner plywood. Adding a weather-resistant sealer can also help minimize distortion. This is especially true when environmental factors, such as humidity or temperature fluctuations, can compromise the structural integrity of plywood boards. Choosing thicker plywood enhances the overall durability and longevity of your projects and provides a more reliable and stable material for various applications.

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