Camper Glass Window Fitting Guide for T5 and T6 (Using a Grinder)
While it is possible to use other tools to cut out your windows, we have designed these instructions to work best with the tools we think you are most likely to already have at home.
To protect your van interior, remove as much as you can and cover anything that needs to stay inside.
Grinding sparks can damage carpet, fabric and windows, so where possible cover these up.
1, We recommend that you protect your van with masking tape and polythene sheeting.
2, Drill pilot holes around the inner panel line
3, With a straight edge draw a line across the centre strut
4, Cut through the strut with a small grinder
5, On the outside of the van, join the drill holes together with marker pen and a straight edge
6, Now from the outside of the van, carefully cut the panel out using a small grinder, following the pen line taking extra care on the corners.
7, Remove the panel carefully. If possible get another person to help you lift it out without damaging the rest of the paintwork.
8, Sand the cut edge of the metal to remove any burs.
9, Apply a rust inhibitor to the freshly cut metal edge.
10, If required you can add some window bond between the two skins and gently knock the inner skin closer with a rubber mallet. This is optional but you will find it makes it easier to apply the U-Trim if this is done.**Please note if you are carpet lining this panel you may choose not to use U-Trim. You can get a neater finish by carpeting over both skins and pressing the carpet edge down between the outer skin and the window**
11, Use the clear glass cleaner / primer to clean the edge of the window and also the panel you are going to be applying it to.
12, Apply the black body primer around the edge of the window
13, Apply the same primer to the bodywork of the van being sure it doesn’t run on areas that won’t be covered by the window.
14, Apply the window bond so its stands about 10cm tall from the bodywork. When applying it to the bottom of the window, try and keep it as close as possible to the U-trim (if used) so it doesn’t leak out the bottom when the window is pressed on
15, Offer the window up as level as possible. Try and press the top and bottom on at the same time. You will be able to manoeuvre the glass a little to get it into the exact place while trying to make sure the gap is the same all the way around. Now tape the window up with masking tape to keep it in place.
The same principles apply for rear quarter windows, tailgates and barn doors.