Ansel's Transformation: I Can See Clearly Now

Ansel has a window!

My buddy Jim came over this week to help me put in a window in the van. I probably could've done it by myself but: (a) Jim has experience with cutting metal and auto body work, (b) it helps to have two people during final fitting of the window (i.e., one inside and one outside), and (c) Jim really likes to help with this kind of stuff!

Having a window in a campervan is essential...otherwise you feel like you're in a sardine can! And, it helps with ventilation. Many van-lifers have multiple windows...2 or more in the sides and sometimes 2 in the back. While it would have be nice to nice to install more than just this one window, windows are VERY expensive! Plus, you have to provide coverings (blinds, shades, etc.) for privacy, and they are a source of heat loss.

Thus, I decided to put in only one window. In addition, I opted for a smaller and "universal fit" window, which saved me a few hundred dollars. I decided to place the window in the galley area. This way I could look outside while I was cooking and doing the dishes...there's nothing worse than staring at a blank wall while washing dishes! This location will also enable some some good cross-ventilation with the ceiling van above the bed.

The install was pretty straightforward. It only took us a few hours, and fortunately we didn't run into any snags. Here were the basic steps we followed:

Make a template for the cut out. Nothing was provided so I had to make a template from cardboard. The first two tries mysteriously were failures, but I got it the third time!
Position the template on the outside of the van where you want the window and mark the cut line with a Sharpie.
Cut the window opening. We decided to use an angle grinder for this. Many folks use a jig saw, but the thin metal walls can wobble terribly with a jig saw, resulting in erratic cuts.
Adjust the fit. This took us at least 5 or 6 tries to get the window to fit perfectly, but it's better to start with a smaller opening and work slowly to enlarge it for a good, tight fit. We (or rather, Jim) used a "flapper wheel" on the angle grinder for this.
Clean up the edges, again with the flapper wheel.
Prime the exposed metal edges.
Prime the surface of the metal for the adhesive.
Apply the adhesive. This is a special urethane adhesive which is actually the same adhesive used to bond windshields.
Insert the window into place and secure until the adhesive sets

While the window is not going anywhere (at least I hope not), I do plan to build some wood supports on the inside to help secure it, minimize vibration, and also provide a base for the future trim.

Inspired by Jim's awesome help, I later cut in...all by myself now...my shore power outlet and water tank fill opening. Things are really starting to materialize!

Thanks so much Jimmy!!!!