Thursday, August 23, 2007

Installing the windows

Scoring the aluminum flashing.


Snapping the aluminum along the score line.


Putting it in the window opening to cover the gap between the inside and outside walls.


First window installed. You can see the additional
insulation in the second window-- the yellow stuff is the
toxic crap and the lovely white is the Tiger Foam.


Installed windows. You can see by the look on Seamus' face
that we were pissed off and exhausted by the time we finished.
We got done after 9pm. Sucked.


So... when you last tuned in, the window openings had been made in the walls of the truck. We now move on to window installation.

We sprayed more insulation into the space between the outer and inner walls of the truck. At first we tried Great Stuff which wasn't so great and probably caustic and polluting. Luckily, the TIGER FOAM! still had some juice and once again worked stupendously. I heart the TIGER FOAM! Can you tell?

Because the windows were made for lesser (and less insulated) vehicles the inside and outside frames had about a 3" gap between them. I decided to use aluminum flashing (the kind that is used around the chimney on the roof) to cover the innards. Very easy to work with-- measure, score with a utility knife, then fold along the score line and it will snap. I measured around the window cutouts to get the length of the flashing strip. We stapled it into place (and of course this took several cursing tries to get it right).

I ground the old caulk of the windows with a motorized grinder and cleaned the outside surface around the windows with denatured alcohol. We applied new caulk and fit the windows into place using self-tapping sheet metal screws to attach the frames together. Unfortunately, whoever assembled the windows in their previous life put the screws in wherever and didn't evenly space them, which sucks cause they are all crooked and random. Something to fix in the finishing stage.

And we still didn't get to the damn roof vent which is still not done. Dammit.

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