Installing after-market window(s)

Difficulty:

Labor:

5.25 hours

Cost:

$572.59

We recommend completing the prerequisites before continuing your journey through the steps:

Rough idea of your layout to make sure you aren't placing the window in any areas that might get covered (eg, bed, cabinet). We wanted the windows for extra ventilation, rather than for natural light, so we decided to put ours as far away from the fan and doors as possible, since this is likely where the extra air will be needed
Avoid any flares or lips in the van that might cause uneven install and create air gaps
Check the weather for rain – most of the glue used will require at least 24 hours to dry (this was a rough one living in Seattle)
Install windows prior putting in insulation and the sub-floor that way...
Debris from cutting doesn't get stuck in insulation and floors
If there ends up being a leak in the window when you water test you won't get the floors and insulation wet
Check that your window has weep/drain holes and avoid covering these in any way! Particularly when you are gluing it during install (can you tell this might have come with experience?)

Safety Tips:

Tape below where you are cutting to help catch metal shards so you don't track them throughout your van and/or home
The parts of the van that get cut can get extremely sharp so you'll want to wear gloves whenever you can and be careful when handling any part of the van that has been cut
Cut the top part of the window first, and before moving to the bottom edge of the window be sure to add a few strips of tape to hold the window in place so it doesn't fall as you cut it out.
If you have a second person, they could use pliers to hold the edge while you cut

Make a cardboard template

Create a template of the window by tracing the inside of the trim ring on a piece of cardoard and then cut it out.

Window placement

Using the template, play around on the outside and the inside of the van and determine where. you want the window to go.

Note: Be sure the template lines up where you want it on both the inside and outside of the van.

Secure the cardboard

Tape the cutout to the inside of the van and drill two holes horizontally from each other through the center of the cardboard template and through the van wall.

Double check the template

Take the piece of cardboard to the outside of the van and use the drilled holes to hang the cardboard on the outside. Determine if the location works for the outside as well - if it does not, make the necessary tweaks to move the window.

Note: Your holes may not be exactly aligned so be sure that the cardboard is facing the correct way that it was on the inside.

Outline the template

Once content, securely tape the cardboard template to the outside of the van. Now take a marker and trace the template on the outside of the van wall and then remove the template.

Prep the cut

If you're using an air-saw, jigsaw, or other cutting tool, now is when you will want to tape the edges of the traced outline to avoid scratching your van while you cut.

Catch your metal shards and shavings

On the inside of the van, secure a trash bag to help catch any of the metal shavings from going inside of your van.

On the outside of the van, angle some painter's tape below the window to help catch the shavings on the outside.

Drill a starter hole

Near the top of the outline you made, drill a starter hole below your cut line. Be sure to use a drill bit that is large enough to let the blade through.

Note: Remember, many of these windows have curves and increase the difficulty of the cut. If you want to practice cutting the side van wall, do it in the middle of the outline you made.

Start cutting

Insert your tool of choice (we prefer an air-saw for curved cuts) into the starter hole and begin cutting across the traced outline. Try to be as precise as possible to ensure the best fit for the window.

Note: The more you cut, the flimsier the metal will get which will make cutting more difficult. Be ready for this and stay focused on your cut!

Note 2: As you near the end, watch out for the metal cutout as it will most likely drop - we don't want it cutting you nor the van.

Test fit window

Insert the window into the freshly cut hole. Be sure it fits how you want it to, if it doesn't trim up the areas that it does not fit properly.

File down the sharp edges

File down the edges of the hole with a metal filer. Be sure these are fairly smooth as you don't want to cut yourself when installing the window... and you don't want to have any jagged edges as that could increase the likelyhood of a leak.

Rust prevention

Wipe down the edges with cleaning solution and then paint Rust-Oleum around the holes bare metal to help prevent rust.

Prep the window

Tape off the window to ensure the bonding primer does not get into places where you do not want it. Once taped off, clean the area with cleaning solution and then spray the Rust-Oleum bonding primer around the edge of the window as this is where the Windo-Weld glue will adhere to.

Prep the van hole

Similar to the window, tape off the window hole to ensure the bonding primer does not get into places where you do not want it. Once taped off, clean the area with cleaning solution and then spray the Rust-Oleum bonding primer around the edge of the hole as this is where the Windo-Weld glue will adhere to.

Practice with the Windo-Weld

This adhesive is tough stuff. We recommend practicing caulking a little line to ensure you can get a continuous, even line.

Note: Highly recommend getting an electric caulk gun if you can.

Add 3M Windo-Weld to window

Once comfortable, evenly distribute the 3M Windo-Weld around the frame of the window.

Note: Be aware if your window has any weep/drainage holes. You'll want to avoid adding a bunch of the Windo-Weld in these areas as it'll cause blockage, and ultimately causing overflow which can lead to water leaks on the inside

Insert the window

Open the window to better handle the window. Once you pick it up, insert the window into the van hole as accurately and evenly spaced as possible. Gently press inward and hold into place.

Note: It helps to have a second set of hands on the inside of the van to help align everything on the inside as it will be difficult to do so from the outside.

Remove excess adhesive

As you press the window in, you will most likely have excess adhesive coming out the sides of the window on both the inside and the outside of the van. Be sure to wipe this off as best you can to make it look as clean as possible.

Note: This stuff is REALLY irritating to try to clean up - just keep at it and power through the annoyance of this substance.

Support the window

Add tape on the outside, and the inside if necessary, of the van to act as a support as the glue dries.

Note: Be sure to read the adhesive's label to know how long it'll take to dry.

Water testing