How to Remove the Reinforcement Strut and Outer Skin from Your camper Van Window
Removing the reinforcement strut and outer skin of your van window can be a straightforward process if you have the right tools and techniques. In this blog post, we'll walk you through the steps involved, ensuring you can complete this task safely and efficiently.
Tools You’ll Need
Angle Grinder with Cut-Off Wheel: This will be used for cutting through the reinforcement strut.
Multi-Tool: Ideal for removing adhesive foam and detaching the strut.
Drill: For creating holes at the corners.
Nibbler: A handy tool for cutting out the majority of the window from the inside.
Sawzall: An alternative tool for making straight cuts if needed.
Jigsaw: Another option for cutting the outer skin, especially when masked properly.
Step 1: Cut the Reinforcement Strut
Start by using your angle grinder with a cut-off wheel. Carefully cut through all the lines you've previously drawn on the van's surface. Your goal here is to cut only through the reinforcement strut, not through the outer skin of the van. If you accidentally cut a little into the outer skin, don’t worry; this area will be covered later.
Step 2: Remove the Adhesive Foam
Once you’ve cut through the strut, you’ll find adhesive foam behind it. To remove this foam, grab your multi-tool and run it down the backside of the strut. This will help you detach it easily. Avoid yanking on the strut to prevent bending the sheet metal or injuring yourself on the sharp edges.
Step 3: Drill Holes in the Corners
With the reinforcement strut removed, the next step is to drill multiple holes in all four corners of the window frame. This step is crucial for tracing the rounded corners from the outside and ensuring you have a clear path for cutting.
Step 4: Cut the Outer Skin
Now it’s time to remove the outer skin of the window. You have a couple of options for this step:
Using a Nibbler: This tool allows you to cut about 90% of the window out from the inside. When you reach the corners, you may find it difficult to maneuver around them due to the lock post. In this case, the drilled holes will help guide your cuts.
Using a Sawzall: This is a great option for making straight cuts from the inside. Just make sure not to jam the blade too far into the van’s frame. You can freehand this cut while following the stamped line, which makes it easy to stay on track.
Using a Jigsaw: If you choose this classic method, make sure to mask off the entire outside area to protect the paint.
Important Considerations
Regardless of the cutting tool you choose, always pay close attention to the lock post. You don’t want to accidentally cut it off, as this can affect the integrity of your van’s structure.
Conclusion
Removing the reinforcement strut and outer skin from your van window requires careful planning and the right tools. By following these steps, you can ensure a smooth and efficient process. Always prioritize safety and take your time, and you’ll have your window frame ready for whatever comes next in your van build project!