If you got stiff enough metal, could you fit it tightly without permanently attaching it with anything? If the chicks can't get to it, maybe some type of metal lath? Like that stuff you mortar stone to? Or maybe just wedge some wood in tightly around it
I'm probably going to have to chat with someone at Ace Hardware about this glue situation. But the more I think about it, if I glue directly to the frame on the outside with the window open I could use clamps. The wood would be less than an inch wide though, sigh...
In this case a picture IS worth a thousand words because I figured it was an aluminum shell but it's fiberglass. No biggee! At HD or Lowes they sell aluminum strips in the window dept that you use to make your own window screen frames. Make a frame and attach your hardware cloth to it, have your helper hold it over the window on the inside, and drive the screws from the outside, through the fiberglass, and into the screen's frame. That should make a neat & professional looking job.
Now that is what I envisioned! The execution is what I have questions with. Maybe some closeups will help in the discussion (if my phone will quit crappin out on me! I hate to admit my iPhone worked better than this android, but maybe its the cheap phone plan, lol).
I attempted that angle once. I tpok off the top layer of frame and tried to cut the hardware cloth to fit into the area neatly. I got the hardware cloth as good as I could in the area and put the screws through the preexisting holes and bent the hardware cloth to adequately go around the screws. What a nightmare it was and I spent hours wrestling with it. Even if in theory I got it to work, I would have to keep it together on the transfer to be upright and continue to screw the frame to the shell in the preexisting holes. At that point I realize the preexisting screws were too far apart (and not at the corners) making it a bad idea.
If I made my own screen, would it still work with the functional window? I guess I'm interpreting your suggestion as a replacement frame....