Window Installation

Saturday, September 17th, 2022

When we first knew we were going to be receiving the van in June, Josh ordered windows for it.  In total, six windows were bought from the Sprinter Parts and Service Store.  It took months to get all of them in at the Oregon shop.  Josh drove down to Tualatin, OR in order to save about $700 in shipping and handling.  He was unable to check the windows since they weren't in boxes and the team at the shop were eager to load him up and send him on his way.  This was on Friday, and we were preparing to do the window installation on Saturday. 

Saturday morning we set out all of the windows and tried to determine by part number and shape where they should be located.  It didn't take too long for us to realize we were missing two windows - the passenger middle and the driver front.   We had six windows altogether, but two of them went to different models of vans.  Josh called the company but they're closed on weekends.  He followed up his voicemail with an email.  We discussed whether to wait until we had all of the correct windows before installing but decided to forge ahead and make due with what we had. 

We taped off the exterior side of the van so no metal shavings or sparks from the angle grinders would damage the paint.  We also taped and covered the sides and floor of the van with plastic so no metal shards would get into the crevices of the van and rust.  Josh found an installation video that we watched several times before making the first incision to the van.  On Saturday we were able to install the rear passenger window. 


Four correct windows and two incorrect ones.

Prepping the exterior of the van. 

The inside of the van once it's all taped off and prepped. 

To start, we  drilled holes in the four corners of the metal.  We followed this with a 1" hole saw so the sawzall blades could fit into the cut and we could maneuver the corners.  Next we used an angle grinder with a cutoff blade.  Once the metal was removed, we used an angle grinder with a grinding stone to round and smooth out the edges.  After this Josh used a deburring tool on the inside edges.  Before adhering the window, we used acetone to clean the exterior surface of the van.  Then primer was daubed on the window and the outside of the van.  We used a Sika flex adherent urethane with a motorized caulking gun (the Milwaukee M18) to caulk the exterior of the van.  Finally we placed the window on the van and used painter's tape (eyelashes) to help secure the window in place.  The windows needed to cure for 24 hours before removing the tape. 

Josh using an angle grinder to smooth out the edges. 

The eyelashes (painter's tape) ready to secure the window.  The adhesive and primer are visible around the window cutout.  

Sunday, September 18th 2022

Having completed one window, we felt more confident with the remaining three.  We cut out all three windows and repeated the process of the first window installation.  It took most of the day but the end result is pretty impressive. 

All four windows installed.  The middle driver and front passenger windows will be installed at a later date. 

Monday, September 19th 2022

A rep from the Sprinter Parts and Service Store called Josh Monday morning and apologized for the error.  The correct windows will be shipped to us at no charge and will be sent directly from the manufacturer.  The incorrect windows we received can be discarded.  We would prefer to try and find someone who could use them though as we don't want them to go to a landfill. 

Saturday, October 1st 2022

We received the correct two windows on Tuesday, September 27.  We had them delivered to my parents' place in Marysville since that's where we have space to work on the van.  Josh went up to help receive the windows and confirmed they were the correct ones. 

On Saturday we  spent a couple of hours prepping the van again - namely taping and putting up plastic sheets.  Josh cut out both windows and we went through the same process as before.  

Josh prepping the outside of the van.  The window to be installed is the driver side middle.

More tape and plastic.  I like to joke that if needed, Josh and I know how to properly dispose of a body like Dexter. 

The interior of the van taped off, covered in plastic, and fully prepped before cutting out the window on the passenger sliding door. 

The exterior of the van.  The metal to be cut is the passenger side sliding door. 

The passenger side sliding door with the metal cut out. 

A view of Josh with both windows cut out. 

The passenger side of the van with eyelashes. 

Sunday, October 2nd 2022

After curing for 24 hours we took the tape off of the windows.  The windows make the inside of the van feel larger and it makes the exterior of the van look really sleek.