I finally got round to the next stage of my tiny camper van conversion; installing windows in the rear barn doors, but it didn't quite go to plan!

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https://thetinycampervan.com/2022/06/...

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👉 The windows I bought: https://www.vanpimps.co.uk/product-ca...
👉 Bosch T118AF Metal Jigsaw Blade: https://amzn.to/3ZcCQrP
👉 Half round file: https://amzn.to/3K1leL5
👉 Step drill bit: https://amzn.to/3LHd4cb

0:00 - Intro
0:24 - Preparing the doors
1:28 - Drilling the holes
1:55 - Cutting the window holes
3:08 - Filing and priming the edges
3:34 - Fitting the rubber window trim
4:53 - Applying the primer
6:00 - Apply the adhesive
6:39 - Attaching the windows
7:55 - Water testing the windows
9:22 - Getting the windows refitted
10:11 - Window reveal

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Now this was always meant to be a standard ‘here’s how I installed my van windows’ video, however I made a BIG mistake and learnt some valuable lessons along the way that I want to share.

My van doors were carpeted, so I used a knife to cut the carpet and foil insulation to remove them, without cutting in the wrong place and destroying the carpet lining, or worse, having to buy new doors.

I used a step drill bit to create holes as points at which I could get my jigsaw blade in, to make my cuts. I used Bosch T118AF metal saw blades. I decided to cut from the inside but it’s probably easier to cut from the outside.

I did my best to tape up the van before I started, but the metal filings got everywhere - I spent a lot of time cleaning later.

I finished the edges off with a hand file, getting rid of any burrs.

After that, I coated the bare metal edges with black primer to protect them from rust.

I could then begin covering the edges with rubber trim. I worked my way around both windows, using a rubber mallet to bang them firmly in place and tucked the carpet edge using a plastic panel tool.

Next, installing the glass. I first cleaned the doors then wiped the ceramic edge down with the activator wipe. It’s important not to let the wipe touch the glass, otherwise it could etch or mark it.

I then applied the primer to the edge of the window openings with the felt brush. I waited 15 minutes for the primer to dry and could look to sticking the windows in place.

The adhesive I used in was Winbond Ultra Cure which comes with a pre-cut nozzle.

Using a caulking gun I applied a thick bead onto the primer all around the openings and used about half a tube of adhesive on the small window and three quarters of a tube on the larger one.

With the adhesive on the van, I stuck the windows down and made sure both were aligned with each other, not resting or sinking onto the paintwork and seated well in the adhesive. I probably spent about 4-5 hours on it altogether. I left the van overnight to cure before driving it.

All sorted…well, not exactly. The final test was to make sure the windows were waterproof, so I got a watering can and began pouring the water over the windows.

A small amount came through each window, but I was pretty unhappy that water was getting in. And this was my BIG mistake. Clearly my sealant skills just weren’t up to the job!

So I was left with 3 options. First, I could try and squeeze some more sealant into the gap between the glass and the van door to attempt to plug the holes. Next, I could try to remove the windows and attach them again, probably using a different adhesive like Sikaflex. But how do you remove windows?

My third option, and the one I went for, was to seek professional help.

After getting a number of quotes I found a company that was experienced, well reviewed and reasonable.

They cut the windows off with a cheese wire. The adhesive - which was a week old - was still wet in the middle.

They cleaned up the windows, re-primed the door, applied a proper, even, bead of adhesive and reattached them to the doors.

So finally I can sit back and enjoy the benefits of having windows in the back of my Nissan NV200 van conversion - hopefully leak free for years to come!

If I had to do this again, or wanted to install other windows, I would definitely consider getting a professional to do it.

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#Vanlife #NissanNV200 #LensOfJames

DISCLAIMER: In this video, I am in no way stating that this is the proper way to undertake the conversion of a van, however after research and experience using the van, I believe this to be the way that is best suited to my van and the way I intend to use it.