Ok, due to huge demand, and a little prodding, this is my window fitting thread
There are a few key facts before I start
Windows and fitting kit are from Vansport and are 80% dark. I aim to fit the remainder once Vansport have them in stock. Meanwhile I have fitted these two. Vansport were great, giving me a specific delivery day a week in advance. They come by courier well wrapped but check the package doesn't rattle before you sign for it.
There are a few things I would do differently next time and thought I should state these here:
1. On the off side window, just before you prime the window opening put a piece of tape in line with the edge of where the finished window will go. This will make the priming and mastic more accurate.
2. Don't put extra mastic in the corners, it stops the window sitting flat on the glass (see last but one photo). Also push the corners in first to stop the glass flattening and keep it in line with the curve of the panel (same photo)
3. The kit was missing the nozzles for the mastic, fortunately I had a spare but its worth checking. The V groove cut in the nozzles needs to quite big. I'd say cut of two thirds of the nozzle so the hole is about 10mm diameter.
To the photo's
Start by masking up the whole area. I used cheap decorators dust sheet. It comes on a roll and costs a few £ from DIY stores.
Next drill a series of holes around each corner from the inside and either side of the centre strengthening bar. Try to drill slightly in from the edge (say 5mm) in.
Next draw straight lines between the holes on the outside of the Van where the window will go. Also drill a hole large enough for the nibbler or series of three holes in a triangle inside the cut line and insert the jigsaw and make a hole large enough for the nibbler. Then you can start cutting. A nibbler will follow the inner edge of the frame naturally but try to follow the line you have drawn.
When you reach the strengthening bar you will have to use a jigsaw, cut straight across from the two holes you drilled earlier.
This is the finished cut. Note the shape of the inner and outer frame differs at the bar, and also from near and off side (not shown)
Repeat the other side (assuming you have two windows) and you now have two holes. This is a good point to mention to keep an eye on the weather!
Now prime the cut edge with something quick drying. I used a hammerite product, see kit below
next break out the fixing kit. The instructions here are good so I wont repeat them. Just check you have the nozzle (atleast one) as you are stuck without it.
I am not going to explain this task other than show the primer in place. Beware there is only just enough for two windows. Wear the gloves, its much easier!! :*
Now to the windows
Next apply the mastic. I cut the hole in the nozzle too small and so in some places went round twice. Try to get the whole bigger. I'd say cut off two thirds of the nozzle. You need a V groove, not a wedge shape. Note my comment at the top about not putting too much mastic in corners.
Now fit the windows, remember not to apply too much pressure on the curved sides before getting the corners flat to the panel, avoid my error at the bottom (see last but one pic) I suspect the primer and mastic should be nearer to the edge and that someone more learned will be along soon to confirm this.
and
As I said above, avoid flattening the window in the middle first otherwise you get a wider gap at the corners like this
Lastly tape each window as you fix it to stop them sagging. You need an extra person as it will sag in the time it takes to tape it from one side to the other. Make sure the tape is tight.
Leave the tape for two hours before removing.
Job Done!
Good luck ITB T:
