XenaCommanders Place

"Participating in Life"

Truck Blog

Christmas Hols 2010 - Week 2 - Windows at last!!!

Posted by XenaCommander on December 28, 2010 at 6:30 AM

After a week of not so good weather...  I did manage to achieve the first goal and fit the hatches...  and even had some down time...  All good.


Goal Two:   Windows Next...

Sunday 26th December:  Boxing Day was a slow start although the weather was fine and going to be hot... I wanted to get up on the roof of the truck and seal the joints that I had uncovered and rust treated a week or so ago.  I had noticed while it was raining the other day that water was getting in through the seams.   Time to remedy this.


You can see here I am applying 3M Extreme Sealant tape...   Amazing stuff (and expensive!!)  but you have to be careful applying it.  Once you have stuck it down it isn't going anywhere.



Once it is stuck down you run over it with a roller and crush it down to seal everything.   Then remove the backing paper..   Amazing stuff should do the trick.


Now it was time for the windows...  I can do maintenance all summer but I want to make some construction progress..   Maybe I have been finding excuses to avoid  making that first cut in the side of the truck...  I don't have an issue with commitment...    really...!!!   no really...!!!

So it was decision time..  Well lets do the bedroom window drivers side so you can't see any mistakes from the road side..!! 


I turned the truck around on the pad and used the hydralic levelers to get it horizontal.   That should make the measuring easier.


Ok..  My dad said always measure twice and cut once..   I think I measured ten times....


The first cut..!!  I hope I got it level...  Too late now...



Around the corners with the jigsaw... 


TK taking pics...  It looks good from this side...  Now to cut the frames still holding it on the inside.


Frames cut..  Now to remove the panel...


XC feeling pretty good...  A milestone reached...

Now to smooth the edges and see if the window fits..   The moment of truth...


Ah hah..!  It all fits..  looking good...   Now the hard part..  to fabricate the frame around the opening...  XC is enjoying the welding and cutting of the metal frames..  great fun...


Frames al lglued in and being held in place by the clamps...  There was no rain forecast overnight so I left them in and will weld them together tomorrow.


Monday 27th December:  This morning I removed the clamps and got set up for welding...   Only to find that my mig wire was nearly out...  and it was a stat holiday and no chance to get a new roll..  Mumble..   So I knew I was going to run out.    Sure enough after welding half of the frames in place the roll runs out..!!    So I spent some time planning for the kitchen window placement..   This means making some final decisions as to where things are going to be located in the finished motorhome..!!        All done but I decided to postpone the cut for another day.    TK and I went for a ride on Xena over to my cache at Adventure Headquarters stopping in to say hi to Annie and Paul...   When we got back I decided to have a quiet afternoon and a break from the truck..  I put the window in place temporarily to keep the forecasted weather out of the truck.


Tuesday 28th December:  Rain...  Rain... Rain...  Another big front went over the whole country so I was relegated to clean up duties...  sweeping up steel filings... and rubbish...  and I even tidied up the garage.. TK will be pleased..!!   The rain was useful in that it showed up a couple of leaks around the hatches...   I will have to add more sikkaflex around the edges to stop water from getting in.   I spe nt the rest of the day measuring up the rest of the windows...  Measuring each one about ten times...  All set for tomorrow with a better forecast.


Wednesday 29th December:  Up early for a run...  Weather fine and clear...!!  Yaay..!  First job today was to ride Xena to Taupo to get supplies..  I needed more welding wire and cutting discs...   I was back by 9:30am and was loading the wire into the welder and it all unravelled off the reel!!!  talk about a birds nest..   Took half an hour to get back together and loaded.   A coffee to calm the nerves...   Then I finished welding the bedroom window frame..   Then the major step..  Glueing it in.



All in place..  looks good..  I need to tidy up the edges of sikkaflex.  This is best done when it is all dry..

Now on to the next window.  I decided to do the kitchen next..  I had already marked it out yesterday so cut it out.


Kitchen window cut..   Note the hatches and bedroom window open for ventilation... It makes such a difference in the truck with the extra light and it is not so hot with the flow of air through the truck.

The rest of the day was spent cutting the existing framing back to allow new framing to go around the opening...  This is laborious cutting and grinding...  Then cutting the new framing to fit around the opening and glueing and welding it to  the wall and existing frame.


By the end of the day I had glued and welded the frame in place... 


I just hope it doesn't rain tonight as I have left it open.   Fingers crossed.

Another fine day forecast for tomorrow.  Hopefully I can get the other bedroom window in.


Thursday 30th December:   Another nice day although cool early morning when out for a run... In the truck by 8... I removed all the clamps and tidied up the window frame and primed the bare steel...   Then the hard job of sikaflexing the window in place..   This time was much better than the first one...  I didn't smudge it so much so not so much of a mess.   By the last window I will have it down pat...!   Yeah right...



Two windows in..   three to go...   plus the round ones..  It is much lighter inside with each window installed.

Xena even made an appearance..!!   She has been banished from the garage while the work is going on...!

Now for the other bedroom window...   And I have a confession to make...!!!  


I stuffed up the measurements...!!!!


After going on about measuring twice and cutting once..  I must have measured about five times... again...  but somehow I must have transposed some numbers or had 600mm in my head for some reason... instead of 500mm..    So on I go merrily cutting out the opening and even trimmed up the frames inside..  then I looked at the piece of panel I removed which was sitting next to the other one removed from the other side..   Hmmm that looks bigger..!!!   Aaarrgghh..!!!!  I had cut the hole 100mm bigger than it should be... 


After cursing and swearing for a while..   Ringing TK in Auckland and venting some steam....  I realised I couldn't do much about it..   I couldn't patch the opening and start again..  It would look awful.. 

The only solution would be to get a window the size of the hole I had cut...   So in the end I had upgraded..!!  lol..  I did actually think to myself after putting in the first window that it was a bit small...    Now I will have a picture window on the left side which will likely be the side the view is on...   Very cool...


So I continued with the framing...  I will order another window from Lotus when they get back in the new year.



All framed up...   I think this size looks better and will have a great view from bed.. lol...   I had to cover it up to keep the weather as the window won't be made until next year..!!   or a couple of weeks at least...

Oh well..  I have made my mistake for the summer...  Learn the lesson and continue..  and be glad it could have been a lot worse.. 


 Friday 31st December:  Rain...  Rain... Rain...   Mumble...  a clean up day in truck and garage...  so much steel grindings...  Just as well I am not magnetised...

Friends Allan and Marge Salmon arrived for a few days in there motorhome...  a great example and an inspiration for XC to get to the end of this project...   One day..!!!.

Saturday 1st January 2011:  Today was the day to put the big lounge windows in...   or at least prepare them for installation.


I got the measurements right..!!   It was good to have a mate check the measurements... Allan seen here filing the edges...


We framed up the right hand side and left it to dry so I cut out the final window.   Progress...


Allan started cutting the frames inside and I cut the last bits I could reach from outside.


Removing the panel... 


So much light in the truck now..   Nice view of neighbours back yard...


Last window framed up and braced in place...


The right lounge window went in last thing in the day and I used the suction cups to hold it in place with weights on to give constant pressure...   Allan is outside cleaning up the sikaflex from the frame... messy job...


All done..  time for Happy Hour....


One more week to go...

Categories: Motorhome Building, General

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