How can I cut through brick to add a window?

Question

I'm redoing a bathroom and would like to add a window (36x12) in the shower. This involves cutting through brick. A contractor I spoke with said he could cut it with a angle grinder (diamond blade?), but wasn't all that confident. The brick would be cut on the mortar on the horizontal but would still show unfinished edges on the vertical. So, my questions are: is the angle grinder an appropriate tool to cut brick, and are there any dos/don'ts for cutting brick? And, What are my options to cover the exposed brick cuts and make the window opening look professional? I won't be able to match the other windows since they have brick detail around the window which I don't think can be replicated

Here's a photo. The window would be aligned at the top of the other windows and be about a 36" x 12" awning

Answer 1

I won’t say I'm an expert; I've worked with someone doing something similar in the past and may at least give you some guidance.

Personally, I would use a concrete saw (larger blade than an angle grinder) and/or a chisel to cut the opening. Make sure you have help as you DO NOT want to drop the removed section(s). You can use these bricks later (see below).

Don't forget the header. I know I'm using the wrong term, but I'm referring to the steel plate that holds up the brick over the window.

I would then use a chisel to remove the halved bricks and either turn them around or replace them with good ones from the removed section.

I would also recommend that you at least talk with a mason. They may be able to replicate the detail work around the window with the bricks from the removed section.

Answer 2

You will be able to use a 9 inch angle grinder with a 230mm blade. I've done lots of them, although I'm a retired bricklayer and can confirm it's very tricky. Go to any hardware store for your masonry blade its cheaper than a diamond tip ($5 to buy one blade, which will do the job). I've never used a concrete saw because they are too heavy and too expensive ($120 a day to hire).

Start by using a plumb level to mark out the area with white chalk. It's not a load bearing wall so you will be ok. Then stand on two woodensaw horses: plank them out with 4 or 5 planks (don't laugh - I always put safety first and never had an accident in 55 years of using the blade). Start by cutting out the perps, not the horizontals; they will come out easier. Then you will be able to take out a couple of bricks from the centre panel to get at it. Once the centre is out, the saw won't cut right through the brick so knock off half the brick then use a lump hammer (ie. mash hammer) with a cold chisel and bolster and an old carpenders saw. Then chisel off the back of the brick - if you are careful enough you can turn the bricks around and still use them after 2 weeks clean down with a 8 to 1 ,8 cups of water 1 cup of spirots of salt 500 ml (from a hardware store).

Use 6 sand to 1 cement to make up some mortar. Mix in a bucket with a couple of inches of water and then add teaspoon of dish washing liquid and stir it up to make the mortar plyable.

Hope this helps.

ps. have an assistant behind you in case the angle grinder kicks - and they will - you must hold it firmly while your offsider can pull the plug ie, pull the socket out. That's how we did it - the best and safe way is to a trady in cheers.

Answer 3

I'm a home handyman. I have done several of these jobs. Firstly you need to cut out the brick to the size of your window frame. When you have done this you will be left with half bricks. These need to be cut out also. You can achieve all of this with an angle grinder either 5" or if you are confident 9" is quicker. Use the grinder to cut the horizontal mortar. For the vertical cut use a masonary drill. Hammer and chisel will tidy up your opening. Oh by the way it is dusty so wear glasses, mask and gloves.