There are several questions you may be asking yourself if you’re thinking about fitting a camper van window…
“Can I do this myself?”
“What if I make a mistake?”
“Isn’t it super scary to cut a hole in the side of my van?”
“Shall I just let a professional do it?”
Before installing our camper van window, these were the questions on our minds, too.
But once we’d figured out what we needed to do; which were the right tools for the job and that all we needed was a little more confidence, we thought “Heck, yeah! We can do this!”
And we to give that confidence to you, so you can install your own bonded camper van window.
We’ve broken down the whole process of fitting a bonded window into just 9 steps. Not only that, but we’ve compiled tables of all the tools you might need.
In addition, we’ve got all your safety measures and preparations covered as well as our tried and tested hints and tricks.
If you don’t want to install a glass window, or if you want to know when it’s best to put windows into your camper, give these posts a read:
A Definitive Guide To Campervan Windows: Everything You Need To Know
5 Stages To Completing Your Campervan Conversion
This post may contain affiliate links. Meaning, if you make a purchase after clicking one, we may earn some commission. This pocket money will help Vandercamp Adventures continue to grow at no extra cost to you. It’s a win win situation!! Learn More…
Table of Contents:
Camper Van Window Installation Tools
Bear in mind that these things are not specifically used for installing windows, they can be used throughout your camper conversion build. So, we’ve included a column detailing their other uses.
Essential tools
| Product | Description | Other uses |
|---|---|---|
| Tape measure | 5m tape measure | - Essential tool for use throughout the van build. |
| Metal files | 9" 3 pack file set | - Filing cut out ventilation holes. - Filing any protruding bolts and screws. |
| Plastic hammer | Soft-faced 16oz hammer | - Installing cladding. - Making wooden drawers |
| Window sucker | Suction cup lifter | - Installing solar panels on the roof. - Can be used as a handle for accessing the roof. |
| Sealant gun | Sealant/mastic gun | - Installing and sealing a sink. - Sealing the edge of the flooring and around the kitchen worktop. - Sticking wooden battons to the walls, flooring and ceiling. |
| Work bench | Folding work station | - Resting tools and materials on. - Cutting wooden battens and sheet materials. |
| Wire wool | Medium grade steel wool | - Prepping wood ready to paint or oil. - Cleaning any metal for painting. |
| Adjustable pliers | Water pump pliers/Adjustable pliers 8" | - Prising open window cutout for U trim to fit. - Removing nails and screws. - Plumbing. - Mechanical jobs |
Power Tools And Accessories
| Product | Description | Other uses |
|---|---|---|
| Jigsaw | 800 watt electric jigsaw: Need higher watt for more powerful jobs. | - Essential tool for a camper conversion. - Cut wooden batterns, wood sheets, metal and plastic. - Perfect for cutting cladding |
| Jigsaw blades | 20 piece jigsaw blade set - metal, wood and plastic | - Cutting out ventilation holes. - Fine teeth ideal for cutting cladding. DO NOT BUY CHEAP BLADES - They can be less reliable and may break easily. |
| Cordless combi drill | Bosch 18volt combi drill with 2x batteries. | - Essential tool - Drilling pilot holes in wood. - Used as a battery screwdriver. |
| Holesaw | 20mm multi material holesaw | - Cutting sheet metal, wood and plastic. - Ideal for cutting holes for gas pipes, water pipes and electric cables. |
| Holesaw set (low budget) | 13 piece holesaw set | - Cutting sheet metal, wood and plastic. - 76mm hole saw is perfect for gas drop out vents. - Ventilation holes through the metal panels. - Sink and shower drain holes. - Heater exhaust hoses. - Cutting holes for installing pipework and electrical wiring. |
| Holesaw set (high budget) | 13 piece holesaw set | - Cutting sheet metal, wood and plastic. - 76mm hole saw is perfect for gas drop out vents. - Ventilation holes through the metal panels. - Sink and shower drain holes. - Heater exhaust hoses. - Cutting holes for installing pipework and electrical wiring. |
Materials
| Product | Description | Uses |
|---|---|---|
| Degreaser | Heavy duty degreaser 5ltr | - Prepping metalwork for adhesive and painting. |
| Cloth/wipes | BIG WIPES scrub and clean 100pk | - Cleaning up any glue, sealant, paint and other stains. As well as the hands. |
| Masking tape | Masking tape 50mm x 50m | - Marking out the cuts for the vent holes. - Marking wood. |
| Dust sheet | Cotton 12' x 9' | - Protect the dashboard and seats from dust. - Catch wood and metal cuttings. |
| Dust sheet roll | Polythene dust sheet roll 50m x 2m | - Protect the dashboard and seats from dust. - Protect areas from paint, oil and glue spillages. |
PPE (Personal Protective Equipment)
| Product | Description | Other uses |
|---|---|---|
| Safety glasses | Grade F low energy impact. Clear and anti-scratch. | - General use of hand tools. - Protection from screws, materials and dust from cutting wood or metal. - Comfortably wear them all day. |
| Safety goggles (Grinding) | Grade B medium energy impact | - Grinding metal. - Cutting wood with an electric circular saw. - Better protection from wood cuttings and dust. |
| Ear defenders | Comfort ear defenders 27db | - When using a jigsaw to cut wood or metal. - Drilling metalwork or wood. BONUS! - You're less likely to be bothered or disturbed by nosy neighbours when wearing them. |
| Gloves | Nitrile foam coated genral use gloves | - Essential PPE for every stage of the camper conversion. - Help to grip when lifting heavy items. |
| Respirator | P3 half face dust mask respirator. | - Protect against fine dust particles like sawdust and metal dust when cutting. NOTE - Not suitable to protect against organic vapurs and gases caused from paints and aerosols. Filters with an 'A' rating are required. |
Optional
These items relate to the optional steps we have included in the build guide. We didn’t use them, but they may be helpful to you.
| Product | Description | Other uses |
|---|---|---|
| Angle Grinder | 240v mains powered,115mm, 900w | - Cutting roof ventilation holes - Installing underslung gas and water tanks - Cutting protruding screws and bolts. |
| Grinder disk: BUY THESE DISCS WITH THE ABOVE GRINDER | Metal cutting disks x5 - 115mm x 4 1/2" | Any metal cutting NOTE - DO NOT BUY UNBRANDED, CHEAP DISCS. They can be less reliable and break easily causing safety issues. |
| Metal drill bit | Bosch 5mm HSS (High speed steel) metal drill bit | - Drilling holes in wood, metal and plastic. - Used for cutting ventilation holes in the van. |
| Metal drill bit set | Bosch HSS (High speed steel) drill bit set - piece19 | - Essential camper conversion drill accessorie tool. - Drilling holes in wood, metal and plastic. |
Our Bonded Camper Van Window
The camper van window we installed in Vandercamp was a bonded, sliding window from Camper Glass.
We chose it because:
- The window opens easily by sliding the glass.
- It can be left open while driving to let more air in on hot days, which isn’t possible with outward opening windows.
- The glass has a tint of 80%, allowing us to admire the view from the inside while stopping anyone peeping in.
- It’s one of the least expensive window options available – ideal if you’re on a low budget like we were.
- Available as a complete kit so it’s ready to install.
- Tempered Safety Glass – E marked to meet strict European standards
| VW T5 Transporter Driver Side Tinted Sliding Window, + FIT KIT + U TRIM | ||
|---|---|---|
 |  |  |
| Passenger Side Opening Window | Window U-Trim | Fitting Kit |
Camper Glass windows come in different sizes depending on your van. The window we installed is specifically made for a VW T5, meaning it perfectly fits the panel.
No matter what size van you’ve got, you’ll be able to find a camper van window to fit perfectly. Camper Glass have a wide range of windows to fit most types of vans.
You can then follow these instructions to install it!
Time and Cost
Like any building project, installation time will depend on your DIY knowledge and experience as well as your confidence in using the correct tools.
The cost involved will also depend on how many tools and DIY bits and bobs you already own.
We were lucky because Jolly is an experienced electrician and all-around amazing DIY-er.
Because of this, he has an array of hand tools, power tools and building work accessories, as well as a wealth of practical knowledge and experience.
Therefore, we only needed to buy the window, fitting kit and specific tools for the job (e.g. hole saw, window sucker, rust paint and degreaser).
Our total cost = £180.00
Remember, any tools you buy can also be used for other stages in the build, so the cost will be spread out over the entire camper conversion.
And at the end of your conversion, you’ll have a handy tool kit to keep in the camper.
Our total timescale = Half a day
Allow a full day to fit the camper van window (with an additional 24 hours for the bond to set). You may not need this long, but it’s better to allow yourself more time so you can go steadily and do the job properly.
Although we set aside a whole day, we got everything finished in about half that time. This is because we’d organised our step-by-step guide and knew what we were doing at every stage.
Safety And Caution
Camper Van Window Installation PPE
When you’re using (or near someone using!) any kind of power tool it is important that you protect yourself with the right PPE (Personal Protective Equipment).
A jigsaw and grinder can be dangerous if not used correctly because the blade or disk can break. If you’re not properly protected, this could cause a serious load of ouch!
Using the correct PPE will protect yourself and others around you. See the table above listing the items we used.
Measure Twice, Cut Once
This one’s pretty self-explanatory, to be honest!
Take your time and measure everything super carefully, so you can cut with confidence. Don’t go at it like a bull at a gate and end up making silly mistakes.
Because when you’re cutting into the side of your van, even a silly mistake is actually a whopper of a mistake!
Preparation
Create A Work Area
It’s a good idea when carrying out any building project to set up a working area. A pop-up workbench, a table or even just a sheet on the floor will work fine.
Your work area should include all the tools and materials (and biscuits!) you’ll need.
That way, everything is there for when you need it; you don’t need to stop what you’re doing to rummage through a toolbox or a shed to find what you need.
Next, unbox the glass and check the fitting kit contents is complete, otherwise you’re not fitting a camper van window today!
Window Installation Preparations
The ideal environment for installing a window is somewhere that’s dust-free and dry. Dusty, wet or damp conditions can reduce the effectiveness of the primer and adhesive when they are being applied.
We installed our window on a driveway, so we had plenty of space to lay out our tools and materials, and to move around. The conditions were still, dry and warm, perfect van window fitting weather, if that’s even a thing.
Protect the area with dust sheets. If you’re working on a gravel driveway it’s a good idea to put a sheet down to catch any bits of metal that will otherwise get lost.
Use a degreaser to clean the area of the van where the window is to be installed. This will remove contaminants and surface oils which can affect the primer and adhesive bond.
9 Step Bonded Camper Van Window Installation
This detailed, step by step guide documents how we installed our camper van window. Some sections have slightly different methods of installation, but the end result is the same.
For that reason, we’ve included alternative and optional steps so you can choose whichever one works best for you.
We must emphasise how important it is to read this step by step guide thoroughly before you begin! In fact, read it twice, just to be sure.
Actually, read it three times!
The steps can be followed as you work but it’s important to be familiar with them so you have an idea about what’s coming next.
STEP 1: Measure And Mark Out
A benefit of installing a Camper Glass window is they require little marking out. This is because they are designed to fit a specific panel on a van, so there’s no positioning work or templates required.
Panel van walls are constructed of a single skin outer layer, with additional support struts and a strengthening beam. The outline of the support struts is where you’ll cut. So your ‘marking out’ has already been done!
However, it’s still a good idea to trace this line with a pen, so you’ve got a solid line to follow when cutting out.
If you don’t choose a Camper Glass window, other window designs may require a template to be made (most manufacturers provide a cut-out template).
Place the window on a piece of card, draw around it and cut it out. Then, use this template to see where the window will be best suited and to outline the cut-out area.
STEP 2: Cut Out The Panel
Don’t worry if you don’t have much jigsaw or metal cutting experience!
Luckily, the cut doesn’t need to be perfectly straight so the odd wobble will be hidden.
But don’t throw caution to the wind! Still cut slowly and steadily, making sure to cut as close to the line as possible.
However, if you do stray off the cut line, start cutting again from a different location, as the jigsaw will try to follow the incorrect line.
Use a fine metal bit and start slowly to get it started. Do not force the blade as it could snag and snap.
Alternative Step #2:2
This method will result in a less smooth cut line because of small bumps where the pilot holes were drilled; also, drilling holes through metal can push out the hole edge, causing sharp points.
If the jigsaw blade catches and pops out of the line, it could damage the paintwork. The same goes when cutting from the inside but damage to the interior walls is less concerning because they will be covered.
Alternative Step #2:2
A small grinder can be used to cut out the hole. However, grinders create sparks so could cause damage to the paintwork and surrounding area.
Ideally, you need some experience using a grinder because if you slip or the wheel ‘grips’, it could cause damage to the paintwork, body of the van and worse, to you.
Alternative Step #2:3
This is optional because an angle grinder creates sparks and can be dangerous to use in confined spaces (inside the van).
STEP 3: Protect Your Hole
Careful now! The cut-out edge will be sharp
Wire wool can be used to clean the metal edge for the paint to adhere better.
STEP 4: Install The Rubber Trim
If the temperature is cold, the rubber trim might be stiff. Place it in a bucket of warm water to soften it up. Ensure it is dry before fitting, otherwise, this moisture could get between the metal panel layers.
The join needs to be at the bottom of the window to prevent any water or moisture from getting inside the U-trim. If the join was at the top or on the side, water could get in, run down inside the trim where it would sit and eventually cause rust to the metal panel.
STEP 5: Prepare To Install
STEP 6: Primer Application
The primer will seal, protect and prep the surface to be bonded. It also creates a better adhesive surface.
STEP 7: Bond Adhesive
DON’T START THIS SECTION UNTIL YOU’RE 100% CONFIDENT ABOUT WHAT YOU’RE DOING! READ AND RE-READ INSTRUCTIONS FIRST SO YOU KNOW WHAT TO DO.
The bond adhesive is strong, sticky stuff. It’s similar to silicone but thicker and stickier.
If it gets anywhere it shouldn’t remove it immediately before it dries. Once it has dried, it can be scraped off with some elbow grease and strong adhesive remover will be needed to get it off your paintwork.
Apply the window sucker, open the window and wear rubber/washing up gloves. These will all give you extra grip so you don’t drop the window. And you’ll look gorgeous in your Marigold gloves!
STEP 8: Install The Bonded Window
Glass windows can be heavy, especially when trying to hold them in place. Don’t be a hero and attempt it on your own; get some help for this next part!
The window can be WIGGLED, very slightly, once it is applied. However, be aware that once its on, it’s on. SO DON’T PUSH TOO HARD JUST YET.
The window will take 3 hours to cure and dry. However, to be safe, it is recommended not to use the van or get the window wet for 24 hours.
STEP 9: Clean And Finish
Recap
Once our camper van window was installed, it completely transformed the feel of our van. Rather than a dark metal box, it was now full of light and air. It immediately transformed the van and started to feel like a proper campervan.
Doing it ourselves gave us a feeling of pride and accomplishment. This confidence spurred us on to tackle other tricky parts of our camper conversion ourselves.
By following this 9 step guide, along with all the helpful tips and guidance, you too will be able to install a bonded camper van window with confidence.
So gather your tools, set up your working area and put your safety specs on.
Are you ready for this?
Heck yeah, you are!
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