In all the whole thing cost about $20. Here's how I made it and what I would do differently next time...
Step 1: Frame
The amount of pipe depends on the width of your window. Mine window was about 5' wide, so a 6' wide frame was selected. A main reason 6' was chosen -- I'll say this now -- is that the awning material (canvas drop cloth) is available in a 6' width.
I would not make the awning much bigger than this without more frame support structures. A 3' gap (like mine) is about the maximum I would recommend. I base this on having watched how it handled windy days.
Don't use solvent/cement yet. You can dry-fit parts for now.
Step 2: Awning Material
So I wanted a little flap to overhang from the front of the awning. Your choice if you don't. Form the drop cloth into an inside-out loop as shown. The drop cloth has a plastic backing; this should be facing out. If you're good with a sewing machine, great! I'm not. I took this to a neighborhood alterations place. They sewed it for me for $7.
When done, you can invert it to canvas-side out.
Step 3: Slide Canvas Onto Frame
Add the mounting elbows (shown in the last pic) but do not glue these yet.
Step 4: Tack the Canvas to the Frame and Mount the Top Portion
With the canvas tacked, the next step is to hang the awning from the top. For this you need to have used T's on the upper corners. The small portion of the T that extends from the canvas is used to hold the awning in place. Go to the electrical aisle and get 3/4" conduit clamps. I primed and painted mine to match the house color. (I had the spray paint already.)
Use #8 pan head screws, about 1". I did not use stainless here either.
The awning should hang straight down.
Step 5: Add the Support Brace
The support brace on each side is similar to the top mounting brace. I did not glue this piece. I think the dry fit is tight enough so that the whole assembly is going nowhere even in a stiff wind. I think I recall one time when one side came off. Your choice if you want to glue it. I didn't.
Step 6: That's It!
What to change, depending on how long you want the awning to last:
- Use a mildew-resistant cloth. The drop cloth mildewed after a month or so. I sprayed some dilute bleach solution, and that helped, but I think I waited too long. (The bleach also probably accelerated the corrosion of the carpet tacks.) I live in a hot & humid climate; if you live in a hot & dry climate this may not be an issue for you.
- Use corrosion resistant tacks.