Yeah, I ran into something similar when I replaced a couple windows in my place last summer. Thought I was being smart by using the low-expansion foam too, but apparently even that stuff can push things around if you're not careful. I ended up with one window that was noticeably tighter to open and close after the foam cured. Didn't have to reset the whole frame thankfully, but trimming back the foam was a messy job—sticky bits everywhere.
I did ask a buddy who does construction about it afterward, and he mentioned that pros usually brace the frames pretty securely before applying foam. He said they'll often use shims or temporary braces to hold everything exactly in place until the foam fully cures. Apparently, even "low-expansion" foam can still expand enough to shift things slightly if there's nothing solid holding it in place. He also mentioned applying foam in smaller amounts and layers instead of filling the whole gap at once, giving each layer time to expand and cure before adding more. Sounds like patience is key here... which admittedly isn't always my strong suit when I'm tackling DIY projects.
Still, like you said, once everything's settled and trimmed up, the insulation difference is pretty impressive. My AC definitely seemed happier after those windows were sealed up tight—especially noticeable during those muggy Tampa Bay summers. Makes me wonder if there's some other trick or product out there that's easier for us DIYers to handle without causing these headaches. Maybe some kind of pre-compressed sealing tape or something? I've heard about those but haven't tried them yet.
Anyway, glad I'm not alone in wrestling with sneaky expanding foam... live and learn, right?
Had a similar experience a few years back—thought I'd nailed it with low-expansion foam, but ended up wrestling sticky foam bits off my hands for days. Learned to always shim and brace first... definitely saves some headaches down the line.
Haha, been there myself with the foam—it sticks around forever, doesn't it? Curious, did you try painter's tape around the window frames before applying foam? I found it helps a bit with cleanup. Also, what's your take on vinyl vs aluminum windows for Tampa's humidity? I've heard mixed opinions from neighbors... still undecided myself.
Painter's tape definitely helps, but honestly, I've found just keeping a rag and some acetone handy is quicker for cleanup—foam's stubborn either way. As for vinyl vs aluminum, I've had both here in Tampa. Vinyl holds up pretty well against humidity and doesn't transfer heat as much, so your AC won't work overtime. Aluminum's durable, sure, but condensation can be an issue. I'd lean vinyl personally, especially if energy efficiency matters to you.