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Old 04-10-2013, 09:30 AM   #2611
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Old 04-10-2013, 09:37 AM   #2612
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Originally Posted by FreeTheBeast View Post
I like the [BMW] blue.
BMW M colors!

That sounds familiar

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Old 04-10-2013, 10:10 AM   #2613
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Old 04-18-2013, 10:29 AM   #2614
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Six windows have just been ordered. One of which is being custom built and will take about 3 weeks.

I'm fixing to cut a bunch of really big holes


Giggity: might you be available to drop by one afternoon and hold a window in place while I attach them? We're going to see if Cheryl can handle it but I've gotta come up with a plan B quickly if Cheryl's not able to hold them in place (and it'll be an emergency because the side of the van will be all opened up!).

It shouldn't take long at that point.

There'd be beer in it for you

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Old 04-18-2013, 11:14 AM   #2615
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What do you plan to use to cut the holes, Geek?
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Old 04-18-2013, 11:57 AM   #2616
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I used this to cut the hole in the roof (didn't work the best)


I used this to cut the hole in the floor (worked great but might not be delicate enough for this job)


I think I'm going to use this as an excuse to buy one of these:


for the window cutting

First I will use a drill with a fine drill bit to transfer the stamping from the inside of the van to the outside (drilling 2308230328 holes.. then play connect the dots). The reason is that the template for the cut is on the inside of the van - but isn't smooth enough to run a jigsaw along (where as the outside is).

Most guys I've read have had good success with the jigsaw. The only complaint being metal shavings. I'm going to put some delron on the feet of the jigsaw to keep it from scratching the paint (if shavings go under it) and I'm going to have Cheryl follow along with my cut with the shop vac to try and minimize the mess.
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Old 04-18-2013, 12:27 PM   #2617
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I'm thinking about some work to the interior, which will mean taking the inner walls out for awhile; thinking that may be the time to do portholes. :scared
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Old 04-18-2013, 12:58 PM   #2618
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Some other folks have suggested a "nibbler" (or metal sheer).

The good side of a nibbler: no shavings/no mess.. it just rolls the cut up like a tuna can.

The bad side of a nibbler: they are SUPER accurate which means super sensitive to input - which means large repercussions for mistakes. I've read a nightmare where a guy let the nibbler "get away".



The nibbler is probably the best solution but as I have no practice/existing experience with one and the repercussions for doing it wrong are significant - I'm going to probably chicken out and use a jigsaw which is a technology I've experience with.

I'll use bed sheets and a shopvac to control the shavings.

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Old 04-18-2013, 01:01 PM   #2619
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I've also ordered a Fiamma F65S awning for the van... so more holes to drill in the roof

I'm really chomping at the bit to get back to work on the van... the Counter Top cutting will be the next item hopefully this weekend.

er... if mother nature would cooperate



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Old 04-18-2013, 04:20 PM   #2620
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Quote:
Originally Posted by Geek View Post
Some other folks have suggested a "nibbler" (or metal sheer).

The good side of a nibbler: no shavings/no mess.. it just rolls the cut up like a tuna can.

The bad side of a nibbler: they are SUPER accurate which means super sensitive to input - which means large repercussions for mistakes. I've read a nightmare where a guy let the nibbler "get away".



The nibbler is probably the best solution but as I have no practice/existing experience with one and the repercussions for doing it wrong are significant - I'm going to probably chicken out and use a jigsaw which is a technology I've experience with.

I'll use bed sheets and a shopvac to control the shavings.

If you mount a small guide you could make a nice job of it.

It's also a perfect excuse to buy a plasma cutter. You know you need one.
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Old 04-18-2013, 04:28 PM   #2621
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A die grinder and patients will do wonders too. However you cut it, paint the raw edge before you put the window in.

sent from my abacus.
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Didn't take me long to sort out the derpapotomous tactic again.
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Old 04-18-2013, 04:31 PM   #2622
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Originally Posted by Big Bird 928 View Post
A die grinder and patients will do wonders too. However you cut it, paint the raw edge before you put the window in.

sent from my abacus.
I can totally see how power tool therapy could be very beneficial for many kinds of patients.









Sorry, couldn't resist.
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Old 04-19-2013, 11:26 AM   #2623
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I can totally see how power tool therapy could be very beneficial for many kinds of patients.









Sorry, couldn't resist.
Yep, my spelling sucks, even worse with auto correct...

sent from my abacus.
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Didn't take me long to sort out the derpapotomous tactic again.
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Old 04-19-2013, 03:34 PM   #2624
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Great Addition!

Nice, Another 6 widows will allow lots of us to line up and see what's going on inside! Looks like a newer ktm 500 in there..or

Do they still make stickers that said "If this vans a rocking, don't come a knocking " ?

Still probably cheaper than buying the passenger version and taking the seats out...

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Old 04-19-2013, 03:54 PM   #2625
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Quote:
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Do they still make stickers that said "If this vans a rocking, don't come a knocking " ?


The passenger version doesn't come with opening windows.
If I had a passenger I'd have to remove the windows to put these in (it would save me the cutting stress though! )
With this setup every window will open down both sides of the van

Like this:


Its the reason I'm replacing the two factory windows I have now too. We're going to have an insert for each window that is black felt on one side and matching interweave on the inside sandwiched on a reflectex core. With the inserts in the windows will just look black from the outside (like the two I have now) and inside it'll look like solid walls.

With the inserts out, 360 degree views for when we camp places like this:






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