Next, cut the front and side lattice panels to size using a handsaw. Why not a power saw? The flimsy lattice panels and staples at each lattice intersection make it unsafe. A good handsaw is fast and easier to control in this application.
Measure, mark and cut the horizontal and vertical retaining strips to length. These support the lattice panels as they sit between the legs during final assembly.
Bring it together
Assemble the front of your screen first, laying out two corner posts and front crosspieces on a flat surface. Attach these pieces using four #8 x 21⁄2" corrosion-resistant deck screws driven through the corner posts and into the ends of the crosspieces. To avoid splitting the wood, predrill all of your holes. Although not necessary, I also countersunk these holes so the screw heads lay below the surface of the posts. For extra strength, apply a dab of polyurethane construction adhesive onto each joint before driving the screws home.
Next, fasten the retaining strips to the inside faces of the posts and crosspieces using stainless-steel finishing nails driven in every few inches. These pieces create a ledge for the lattice panel. Once the retaining strips are secured, fit the lattice panel into place and secure it with more nails driven at an angle through the lattice into the corner posts and the crosspieces.
Stand the assembled front panel up and repeat the procedure for the two remaining sides.
Apply a few coats of oil-based, semi-transparent stain to all surfaces. The stain helps guard the wood against sun and water damage. It also helps slow down the development of a grey, weathered colour as the wood ages.
Installation is simple. The screen is self-supporting—it just sits around the air conditioner. However, you may have to dig out some dirt around the posts so all three sides sit level. Drive 12" galvanized spikes into the ground beside each corner post to hold the unit down against the wind. Then secure each post to a spike with a nylon cable tie to prevent the screen from shifting.
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