Sprinter van: Windows redux

Way back in July, our first project on the van after detailing the crap out of it was to cut a bunch of giant holes in it. We had to install our roof fan and a pair of windows. At some point before we put up the walls, K suggested we test the windows and fan for leaks. It would be impossible once the panels were installed. So we did. The fan passed the test. The windows, however, did not. We spotted drips coming from the bottom of each window. Bother all. K started doing some research. 

Neither window came with any instructions. In their respective boxes was a window, a metal flange (trim ring), and a bag of screws. Go. 

Turns out, after YouTubing a bit, she discovered people had built their own spacer rings that would fit between the van’s skin and the metal flange. The thin sheet metal wasn’t thick enough for the screws to tighten down the trim ring and create a tight enough seal. Those folks had built their own spacer. So that’s what we did. 

Fortunately, we had lots of scrap wood lying around, including some quarter-inch plywood. It was a quick matter of tracing the sheet metal cutouts we had kept as templates before painting them with leftover black spray paint we also had, well, lying around. We then glued the spacers to the inside of the van.

After ordering some more butyl tape, we reinstalled each window. Cranked down on the fastening screws sort of like it’s done with lug nuts: opposite screws, going around the trim ring in a circle. 

It was time to test. 

K got out the sprinkler and aimed it at each window for a few minutes. The good news: No leaks! We were good to go. Apparently the key was knowing to have some scrap quarter-inch plywood lying around and to use it for making a hack spacer. Now we know. And if you’re looking at installing a window after cutting a giant hole in your van, you do, too.