exactly!
knightfly said:
"Yes, it will need handles--in case anyone wants to try to pick it up " - Handles? HANDLES??!? What about the freakin' CRANE to lift it?
Yeah... In fact, that was foremost on the mind (after caulking it, and realizing that there was NO WAY IN HELL I was going to beable to lift it

) Thinking about ways to install it in the window (empty) FIRST... then... what I'm thinking of to fill it is... measure the exact amount of sand needed for each of the three cavities, staplegun thick pieces of burlap to the inside of so that there's a gap at the top of each, fill each one (the sand will bulge out -- like big, rectangular beer guts

) and then push the final piece of hardboard into place.
Any better suggestions on how to fill that sucker up? So far, there's cutting holes in the cross brace and top, putting it into the frame, then filling it (don't like that), and the burlap idea. Either that, or I could just fill it, close it up, and have six guys with no regard for their lower backs help me lift it into place
Maybe you should figure out a way to mark where that cross-brace is, so when you move you could just cut a hole above the brace and vacuum out the sand with a shop-vac or something
That's actually a great idea. Thought about cutting holes in it to let all the sand out when moving, but the vaccuum idea makes even better sense. I wonder if you could use a sandblaster, or something (like a vaccuum in reverse) to fill the sucker in the first place. It would compromise the design a bit, but would be relatively painless... Hmmm...
Chad