Window Installation for Your Van
Cutting the body of your van to add windows sounds like the worst possible task. Yet, once you know what you are doing, there is no reason why this part of the job should be more intimidating than any other.
Here's a quick guide to installing windows. We'll be focusing on the half-slider windows you often see at the rear end of many conversions. They are easy to install and make a big difference for your build.
Photos courtesy of Vanlife Sagas
WHY SHOULD YOU INSTALL A HALF-SLIDER WINDOW?
Adding windows to your build isn't just a design choice. Of course, it will bring more light to your van and make it look comfier. However, you need to remember the many roles windows have in a conversion:
1) TEMPERATURE MANAGEMENT - At Vanlife Customs, we can install air conditioning units. However, windows can help you stay fresh for a fraction of the price (if it's not 104˚F outside).
2) HUMIDITY MANAGEMENT - Have you ever cooked pasta in a van that doesn't have windows? The steam from the boiling water turns your vehicle into a mobile sauna, and you don't want that. Windows will help you get rid of this damp feeling quite fast.
3) AIR QUALITY - Let's be honest: air quality in a van is crucial. Have you ever let something burn on the cooktop, or rot in the garbage can? This small space needs to breathe, and windows will help you maintain your air quality.
Combined with a MaxxAir fan, those half-slider windows will allow you to vent your van interior with great ease.
WHAT YOU NEED TO INSTALL THOSE HALF-SLIDER WINDOWS
Grinder
Nibbler
Drill
Step Drill Bits
Brush and Powderbond Primer
Screwdriver
Here is what you get in when you buy a half-slider window:
Screws
Trim Ring
Window with sealant
You don't need to seal these windows - They are clamped to the body of your van with weatherproof material and screws.
PLACE AND MEASURE YOUR WINDOWS
Yes, as simple as that. Use the trim ring provided in the window package to "place" your window on the body of your van. We recommend doing this from the inside because you will have a better idea of where your window has to be located.
PRO TIP: Yes, you will probably have to cut some metal reinforcements of your van's walls. See step 02.
CUT THE REINFORCEMENTS WITH A CUTOFF WHEEL
Carefully cut the reinforcements that are in the way of your future window's location. A simple trick would be to slowly approach those reinforcements while the wheel is at full speed to control the depth of the cut. If you cut too far or let the material get too hot, you will damage the exterior paint and wall of the van.
DRAW THE WINDOW LOCATION ON THE WALL
With the trim ring, draw the window location on the wall of your van with a marker. Make sure the drawing is levelled with the van, otherwise, you might install your window with a slight angle.
DRILL HOLES WITH STEP DRILL BITS
Punch four holes along the inside of the ring you just drew with your step drill bits. This will allow the nibbler's head to move into position and start cutting the wall of your van.
PRO TIP: The stress level at step 04 is usually very high. But trust your judgement and the ring you just drew - Your window will cover all of the holes you are about to make.
CUT YOUR WINDOW HOLES WITH A NIBBLER
The nibbler is a fun and easy tool to use. It is basically a 360˚ powered scissor that cuts through metal. It will literally eat the metal sheet in the direction you push it, so be careful. With the nibbler, cut out the rim you drew on your wall. Make sure you keep the cut in the interior of your drawing.
You can also use a jigsaw or air saw with a fine-tooth metal blade for this part.
GRIND AND PRIME
To avoid corrosion around your window, you now have to grind and seal the metal cut you just did. Use the grinder to take off any burrs and clean up your cut lines. When that is done, use Powerbond Primer and a brush to prevent rusting.
PUT WINDOW IN PLACE
While your friend is holding the window in place from the outside, use your drill to screw some small pilot holes from the inside using the Trim Ring: it will show you where the screws are going.
PRO TIP: Make sure your window is still levelled by pushing its extremity up and down before drilling pilot holes.
SCREW WINDOW IN PLACE
With a screwdriver, gently screw your window in place using the pilot holes. You will want to gradually tighten everything to avoid twisting the window frame, or the body of your van.
PRO TIP: Check that your window is sealed by hosing the outside and checking for leaks on the inside.
There you go! You now have windows at the back of your van that will keep you fresh during the warmer days! If you want a video example on how to install those half-slider windows, head to Vanlife Sagas’ Youtube Channel: they recently installed two of those on their new build!
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