Making arched solar screens will save money over ordering them from a manufacturer. The special screen mesh will protect your furniture and flooring from the sun's harmful rays and cut energy consumption by keeping the house cooler in summer. Solar screens provide more privacy and block glare. A quality screen that will last a long time can be made in about four hours with materials you can find at any home improvement center.
Make a template to match the arched window. Hold the construction paper over the arch and cut out the outline of the window frame along its outer edge using a box cutter. Cut slowly and carefully so the template does not tear. It must be a good representation of the window from the outer edge of the window frame to work properly.
Place the template at the top of the sheet of plywood and carefully trace the outline of the window. It might be necessary to place some small objects, such as paperweights, around the edges of the template to hold it in place and flat against the plywood while tracing the outline of the window. When finished the outline on the plywood should be the exact shape and size of the window. Repeat this process on the bottom half of the sheet of plywood or on another sheet of plywood if necessary.
Mark the center of the bottom edge of the outline on the plywood and measure 1/2 inch in from that mark. Using a straightedge, draw a parallel line 1/2 inch in from the bottom edge of the outline all the way across from one side of the outline to the other. Measure 1/2 inch in from the highest point on the top edge of the arch and mark that spot. Using the marks made at the top center and bottom center of the outline, set the compass to create an arch outline 1/2 inch inside the first arch outline. Repeat the process with the second outline on the plywood. Now there are two completed outlines on plywood, one for each side of the screen.
Cut the outlines on the plywood using the jigsaw. Begin with the inner outline to prevent the screen frame from breaking. If the outer outline is cut first the frame will likely break as the inner outline is cut. Repeat by cutting the other outline on the plywood. To cut the inner outline, drill a hole somewhere along the inner outline big enough for the jigsaw blade to fit through to begin cutting.
Assemble the frame and screen. Lay one side of the frame flat and stretch the screen across it. Use the staple gun to staple the screen in place on one side of the frame. Put the staples in about 2 inches apart and pull the screen tight as you put in each staple. Place the other side of the frame over the screen, lining up both sides. Nail the frame together using 1/2-inch nails placed about 4 inches apart. Make sure the nails are spaced so they do not hit the staples.
Cut away any screen that is protruding from the outside of the frame. The frame can be painted to match the window or any suitable color. Once dry place the screen over the arched window and gently wedge 1-inch finishing nails in at the top, bottom and sides to hold the screen in place.