Plasma Cut to Perfection
To make our patches, we carefully measured and used a plasma cutter to cut pieces of steel that corresponded with the various window gaps. These were then tacked in place using a MIG welder, and then carefully caulked on both sides. We used a thin plywood backing to reinforce the sheet metal, and sprayfoam to hold it in place, as well as fill any remaining small gaps. This was followed by a 3/4" hard foam insulation, and another sheet of plywood.
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