So - you've got a nice shiny panel van with no windows... and you want to put windows in to make it a camper van.  What are your options?  Well, you can either pay someone else to do it or you can do it yourself.  It isn't that difficult to do yourself.  No really!  But it does involve a fair degree of confidence to cut a big hole in the side of your van.  It's not really a question of "what happens if I get it wrong", but more "whatever you do - don't get this wrong!".

How to Fit Campervan Windows Yourself

Van Window Types

There are two main types of ways of mounting windows - bonded windows, or 'rubber-mounted windows'.  Bonded windows are the sort of back window you would get if factory-fitted on most new-style vans (e.g. T5 volkswagens and Transits after around 2000).  The bonded style windows generally give a bigger field of vision, and tend to look more 'modern' and flashy. These windows are basically panes of glass stuck or bonded onto a sticky strip on the metal of the van - the only thing holding them on is glue (i.e. there isn't any rubber, clamps, or screws actually holding them in). If you have a new-style van, you can get bonded windows put into it but I wouldn't recommend trying to do it yourself - they tend to be significantly more expensive (around £450 for a side window for a VW T5 I think?) than the rubber-mounted ones.

Rubber-mounted windows are slightly more 'old-school' and most van manufacturers no longer use rubber-mounted windows on factory-fitted windows.  Having said that, there is absolutely nothing wrong with rubber-mounted windows and they are much cheaper to have put in professionally, and the only option for most do-it-yourselfers.  With rubber-mounted windows, once the hole is cut in the side of the van, a thick strip of rubber is slotted onto the metal of the van and this provides a frame for the glass.  The pane of glass is slotted into the rubber frame such that the glass is held in place by the rubber.

             Rubber Mounted Van Side Window                                  Bonded Van Side Window

Standard, single-glazed window units generally cost around the £90 mark, with sliding versions usually coming in at more like £120.  I have a fixed pane of glass in the sliding door of my van, while on the other side above where I have the stove I've fitted a sliding window as it helps allow the steam to escape.

Fitting Rubber Mounted Windows To A Panel Van

So, you want to know how to fit windows into a camper van?  The steps are pretty straightforward:

1. Buy the window (plus the rubber, bead, sealant, and bead tool)
2. Cut a hole in your van
3. Put the rubber onto the metal
4. Put the window into the rubber
5. Put the bead into the rubber
6. Seal it
7. Go on holiday!

When you're buying the window, make sure you are going to be given enough rubber strip and bead to fit around the window. You will also need some sealant material - windscreen sealant is best as it remains flexible - you apply this with a gun as if you were sealing round a bath (note that silicon sealant is different from windscreen sealant in that it solidifies rather than remaining pliant).  It's also extremely important that you get a rubber bead insertion tool - the first time I fitted some windows I did it without this tool and believe me when I say it is not worth the pain!  Do not start this job until you have got one of these tools!

Other tools you will probably need are:

• an angle grinder
• a jigsaw with lots of long metal cutting bits (you will probably break quite a few!)
• plenty of masking tape (some wide tape is useful)
• a file
• a good sharp knife
• some big bits of cardboard for templates
• some paint - something to protect the bare metal (hammerite or equivalent).

Creating A Template for your Van Window

First of all, you should create a template out of a big piece of cardboard.  Place the window pane flat on the cardboard and draw around it extremely carefully.  Move the window somewhere where you're not going to break it, then check that the length and width of your drawing matches the stated dimensions of the window pane. The hole you're going to cut needs to be slightly bigger than the pane of glass, so that there is space for the rubber - this may vary but with the windows I have put in the magic number is 7mm extra all the way round (check this with the glass manufacturer).  Measure 7mm out from the line you've drawn at regular intervals all the way round, then join those dots up - you should end up with a shape exactly the same as the pane of glass except 7mm bigger right round. Now cut the template out with a sharp knife (remember not to wreck your new carpet at this point!).

Remember at every point that this is a precision operation!! The template must be EXACTLY the size you want it to be - draw precise lines, and measure at every opportunity. The template should be 14mm longer and wider than the pane of glass.

Preparing The Van

Most panel vans are designed with obvious places where windows would go - there are usually 'window shaped' sections in the panels where they would have put windows if the panel van had been a minibus version.

Obviously you need to be able to get at the metal, so take off any ply panels and insulation etc. Often you will find a metal strut going up the middle of the window shape - these are designed to stop the side of the van acting like a wobble board. Before cutting the hole, you are going to have to remove this strut. This may differ from van to van, but the easiest way I've found is to use an angle grinder to cut the top and bottom of the strut and then cut away anything sticking the strut to the metal. Be super careful with the angle grinder - you only want to cut through the strut and NOT the side of the van!!

You'll also notice I went for the window on the sliding door first.  The idea here is that if you do muck it up first time (which you won't) then it would in theory be easier to get a replacement door than a whole new integrated side panel!

Cutting The Window Hole

This is it!   Position the template within the window shape in the van - the template should sit within the double skin of the van so that you are only cutting through a single thickness of metal.  Blu-tak the template to the panel and draw or etch around it - once again, this is a PRECISION task!  Measure and double measure the etched shape you've drawn and prepare yourself mentally for what you're about to do - this is your LAST chance to change your mind and go and enlist some professional help.  If you're using a jigsaw to cut the hole, drill a start hole inside the scrap area of panel.

You've done it now!  Cut along your etched guideline as exactly as possible with the jigsaw.  One other thing here is make the effort to get GOOD jigsaw blades, ones for cutting thin metal.  I went through packets as the ones I used weren't quite right and kept breaking.  Just cut slowly, the rounded corners take extra concentration but a jigsaw is a surprisingly user friendly tool.  And 'Voila' - you should have cut out a nice window-shaped piece of metal from the side of you van.  A great tip here is that while you're cutting the hole, after every foot or so of cut put wide masking tape over the cut line and on both sides of the metal - the masking tape stops the loose bit of metal panel vibrating too much and should hold it in place as you make the last cut.

File down any really rough edges, measure the hole again (though if its too big - you're on your own!), and that's you ready to fit your window.

Fitting and Sealing the Window

So now you can slot the thick strip of rubber (ours came with the windows - check this or you may need to buy it separately) onto the metal of the van as this gives you your frame for the glass.  You obviously need to cut the rubber to the right length - try and make it slightly longer so that you end up with a really neat butt joint.  Once the rubber frame is in place you need to slot the pane of glass into the rubber frame such that the glass is held in place by the rubber - professionals make this look super easy, but the first time you do it its probably going to seem pretty epic - try and make sure you've got a friend there to help you hold things and work the glass into place.

You're nearly there.....but now you need to secure the window in place.  You have just been able to slot it into the rubber (fairly) easily.  Without some kind of fixing there is no reason why it can't just as easily fall out!  Here you need rubber beading and the beading tool.  Basically you use the tool to fit the beading into the centre of the rubber frame (see photo above).  This pushes the frame out creating a more secure window seal.  A bucket of warm soapy water also helps to keep the rubber more pliable.

At this point most people also put sealant under the frame although you don't absolutely have to.  Remember you need proper window sealant and you basically push the nozzle up and under the rubber frame, squeezing a thin, and as equal as possible, amount round the whole frame.

So that's you done?  Well, not quite....

Cleaning Up

The big thing with putting in windows and in fact, cutting any metal in your van is that you will generate hundreds of thousands of tiny metal filings.  These little bits of metal get everywhere and will rust over time if left in your van.  Hoover, brush and hoover again to try and get rid of as many as possible.  This is one of the key reasons why it is good to do any drilling or cutting first, while the van is still a shell as it is easier to get at all the little nooks and crannies and clean out any filings.  Once cupboards and floors are fitted this is pretty impossible and you will miss some, only to find a nice pile of rusted metal if you come to lift up the floor in a few years time!

If you have got this far - WELL DONE!  Fewer and fewer people take on this task themselves it is daunting but also pretty satisfying.

Van Window Companies

If that all seems a bit much and you don't fancy fitting campervan windows yourself there are a range of companies out there who will fit windows for you.  The one things is they are now all tending towards the new bonded style windows and very few will probably work with the cheaper rubber mounted alternatives.

Questions 

Q: How to choose between bonded windows and rubber mounted ones?

A: This depends on money and personal taste - My personal feeling is that rubber mounted windows look more 'camper-van' like, whereas bonded ones make the van look like a plush minibus. I reckon you pay twice as much for professionally fitted bonded windows to rubber mounted ones, and I reckon if you fit them yourself DIY rubber mounted windows will cost around a quarter of the price of professionally fitted bonded ones.