Why I Chose to Install My Own Windows
When I decided to go for it and build out a campervan, I was torn between doing a full DIY build versus hiring a company to build it out for me. I enjoy working with my hands and had some carpentry experience from my days in the Florida Keys and living on a sailboat, but I had never taken on a project quite as large as this before. I also didn’t have a ton of spare time on my hands to get it all done fast enough (I wanted to hit the road within a few months). The two things that intimidated me the most about a DIY van build were cutting giant holes through the exterior for the campervan window and vent fan, and wiring all of the electrical components.
After a lot of research and a few phone calls, I decided to hire Boondock Van Co. in Asheville, NC to tackle the majority of the build, but wanted to do some things myself before handing “Vanyasa” (my van) over for completion. Since cutting holes is the first step in the van build process, I decided to just go for it. How hard could it be? Luckily, my friend Conor, an aerospace engineer, decided to tackle this project with me. I learned some valuable skills and wanted to share the process with you. This is a step-by-step guide with information on the tools and materials needed for anyone interested in installing slider bunk windows in a campervan yourself. With a little confidence and the right tools, you’ll be installing your own campervan window in no time.
What Are Bunk Windows?
Bunk windows are small sliding windows that are often used to provide good ventilation in the sleeping or “bunk” area of a campervan.
VWD Overlander Series Bunk Window
This step-by-step installation guide is specifically for the Van Windows Direct VWD Overlander Series Half Slider Van Bunk Windows in a Ford Transit 250 medium roof van, but can be loosely applied to other similar window installations. The VWD Overlander Bunk Windows are easy to install, can be used in any van chassis, have an aluminum frame, solar privacy glass, and a sliding bug screen, and are a popular option for camper vans. Other great options to shop for slider bunk windows in the United States include DK Hardware and Campervan HQ.
Disclaimer: This blog contains product affiliate links. I may receive a commission if you make a purchase after clicking on one of these links. I’m careful to link to products and retailers that I use myself and recommend.
Half-Slider Bunk Window Installation Steps for Ford Transit 250
Step 1: Buy Windows
Decide on your window size and order your windows. The VWD Overlander Series Half Slider Van Bunk Windows come in three different sizes, so you’ll need to figure that out first. I decided to go with the 31×10 inch window for both my kitchen and bed bunk windows. Depending on which specific windows you order for your van build, you may need to double-check that you buy the right window for the right side (passenger v.s. driver side). This is important because the opening needs to go to the back of the van for direction of travel and there are also little drainage holes in the bottom. The great thing about the VWD Overlander Series Half Slider Bunk Windows is that they have a unique universal fit, meaning you can flip them as needed to have the opening facing the correct way, and then once the orientation is decided you can install the drainage plugs into just the top.
Step 2: Placement
Figure out where to place your windows. For the kitchen window, we took two measurements to figure out where to place the window. These measurements should take into account space for insulation, flooring, ceiling, cabinets, counters, etc. We measured from ¾ inch off the ceiling brace (rib) to the bottom of where the upper storage cabinets would be, and then from 2.5 inches off the floor to the top of the kitchen counter. Then we measured the distance between those two points to decide where the centerline of the window should be.
Step 3: Make a Template
Trace and cut out your window transfer template on a thin piece of cardboard using a sharpie and an X-Acto knife. Specifically, you will need to trace the perimeter of the clamp ring. Be sure to use the clamp ring’s edge that matches the window’s aluminum frame edge (the aluminum frame that goes through the wall).
Tip: place weights inside of the clamp ring on top of the cardboard to prevent the cardboard and ring from sliding around as you trace your template.
Step 4: Transfer Your Template
Tape your cardboard window template into your van and make a few light marks along the top and side edges to mark the location of the template onto the wall of your van. You can use a measuring tape to double-check that the template lines you have drawn are level with the ceiling of the van. Make adjustments as needed. Then, remove your template and place a few pieces of painter’s tape next to those marks you made on the van.
Use a straight edge ruler or meter stick to draw a straight line, transferring those guiding marks you drew onto the painter’s tape. This should form a roughly 10 x 31 inch rectangle.
Tip: we used light green tape so that you can easily see the small lines drawn on the van through the tape. This makes the transfer process much easier than using standard blue painters tape.
Step 5: Round the Corners
Trace a template for the rounded edges of the window. Line your radius template up with the lines of the rectangle you drew and trace the template onto the van wall at all four corners of the rectangle.
Step 6: Cut Braces
If any factory-installed window braces are in the way, you will need to cut those out before you can cut the hole for your campervan window. Be sure to account for overhang space to fit the clamp ring. After making these cuts, you may need to use an X-Acto knife to cut the brace free from adhesive on the backside.
Step 7: Drill a Hole
Along the top guideline, mark a dot using a sharpie that is 5 inches away from one of the side edges. Drill a small hole in that spot. This will allow you to start transferring the template from the inside to the outside of the van.
Step 8: Make Rectangle on Outside of Van
Using the hole you drilled as a guideline, make a 30 x 10 inch rectangle out of painter’s tape. Remember that the hole you drilled should measure 5 inches from the closest side of the rectangle (and therefore should measure 25 inches to the other edge).
Use a measuring stick or carpenter square to draw your rectangle onto the painter’s tape. Use measuring tape to check that the horizontal lines you are drawing are level with the top of the van. Make adjustments as needed.
Step 9: Round the Corners
Repeat Step 5 to round the corners of your rectangle on the outside of the van.
Step 10: Cut a Hole
Use a fine-tooth jigsaw to cut out your van window hole along the lines that you drew. Once the hole is made, dry fit the window to make sure it fits the hole.
Step 11: Sand, Clean, and Paint
Use an electric sander with 80 grit sandpaper to get rid of sharp edges around your window hole. Then use 220 grit sandpaper to smooth it all out.
Wipe the interior, exterior, and inner surfaces of the hole you cut down with isopropyl alcohol.
Put on two coats of primer (following the instructions on the paint can), then put on two coats of paint (following the instructions on the paint can).
Step 12: Weather Stripping
Wipe down the sides of the window and add the weather stripping (weather stripping is included with VWD Overlander Series window purchase).
Step 13: Install the Window
Have one person fit the window into the hole from the outside of the van, while a second person fits the clamp ring into the hole from the inside of the van.
While the person outside of the van holds the window firmly in place, the person inside the van should use a drill to loosely secure the self-tapping screws (screws included with VWD Overlander Series window purchase). You do not want to tighten all the screws right away. You can go back around after all screws are inserted and tighten down each of the screws by hand using a screwdriver to ensure a proper seal.
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