Adding Side Windows

Ribs removed… I noticed that on pictures of OEM windows, the back rib remains and the glass is in two pieces. CRL glass is all one piece…7′ long!

I made a template from 1/4″ plywood. I cut it the size of the window glass, then transferred measurements to cut the hole. Figured it would be easy to just attach the whole template to the wall of the van and cut along the pattern.

Worked great.  Window fit on the first try.  It was worth using a $20 piece of plywood to create a solid one piece pattern.

I drilled two 1/4″ holes in center area and bolted the template in place so it wouldn’t move while cutting.It made the job a lot easier, and the shoe of the jigsaw rode on the plywood, so no scratching of the paint. The other side will use the same template (other side of plywood facing out- same pattern) and I just need to cut a piece off to fit over the track for the sliding door. Medium TPI metal cutting blade worked well.

I used some high-tech drop cloths to keep metal bits from damaging the paint on the sidewall.

We removed the window after a test fit, and used a grinder to remove about 1/16″ at one end of the top to match existing window, then painted on a thin coat of paint to avoid rust. Not sure if needed, because the seal is pretty tight, but can’t hurt. Tough to paint the edge, but I got a thin coat on.

Inside view… window in place (pardon the reflection coming thru the sliding door glass)

Outside view

When I started researching windows, posts on the Promaster Forum help me plan my install. I appreciate all who shared their work!

Special Thanks to Don Masso who helped with thinking through the project, and the install itself.  The glass weighs about 60 pounds and is 7′ long and 2′ high.

The other side pictured here, finishing the conversion from cargo van to window van!

Cutting the hole…

Voila!