Windows Phase 2.
My friend Mike is visiting. He recently sold his home and went full time in an RV. Follow his exploits at
askmikemoore.com Mike graciously offered to help with the project. With some friends, that would normally mean hanging around talking and occasionally getting a few items checked off the list. Not so with Mike. He walked into the house the first morning at 7am dressed for work and hasn't stopped since. Together we have made some serious progress in a short amount of time.
I have 4 big windows going into the truck. They will all be mounted up high so you can see outside without bending over. This has always bugged me in other campers so it's time to address it here.
First step was to cut out the larger window on the drivers side so we could use the plug to fill the window hole on the right side. Here's a shot of the hole after new supports are welded in.
And the new look from the outside.
Now for the passenger side. Old window out first.
Next, measure 14 times then cut the plug to fit the new space. You wouldn't believe the amount of aluminum flying around this place right now.
We were very careful and got the plug in with only a 1/16th inch gap in most of it. Then Mike came up this this great idea to tack it in flush. We drilled several holes between the two pieces of metal and bolted a piece of steel on the outside and piece of aluminum on the inside. I then welded the inside piece in place and the plug was flush.
And now the plug is in and solid so lets cut some of it back out.
Here's a shot of the framing that went back in. The 2 x 2 aluminum is all attached to the skin with vhb tape so it's near impossible to remove without bending up the skin. Because of that we left the bracing intact and added to it. I really wanted to put more bracing in there to make it look better but it just wasn't necessary. We made sure the loads were distributed properly without adding more weight.
Passenger side finished except for the gap sealing on the plug. Looking kind of busy on this side but certainly moving away from the ambulance look.