Wondering how to install Polyvision Aero windows into your van conversion? Well I got you! This guide explains the full Polyvision Aero Window Installation process and what we learned or would do differently next time.
When we first got our Polyvision Aero Black windows from Magnum Motorhomes, we were a little perplexed as to how to install them. The Polyvision window installation guide is available to download on their website. However it is only images and we still struggled to figure out what was what.
So I’m writing this to hopefully help anyone else who is wondering how to install a Polyvision window into their van conversion.
We installed our Polyvision window into a Peugeot Boxer, but the same concept applies to any van.
Link to buy our Polyvision Aero Windows (we used 900 x 500 and 700 x 350mm)
What You Need To Install A Polyvision Aero Window
- A Polyvision Aero Window (duh)
- Sikaflex 512 (or Sikaflex 212)
- Blankets (to protect your seats and floors)
- Jigsaw
- Metal Cutting Blades
- Drill
- HSS drill bit
- Angle Grinder
(For a video Tutorial on How To Install A Polyvision Aero Window check out our IG Stories)
How To Install A Polyvision Aero Window
1. Make A Wooden Frame For Your Polyvision Aero Window
Because the windows are designed to go into a caravan or motorhome, rather than a thin panel van, you’ll need to make a frame to increase the thickness of your wall at the point the window will go in to the hole.
We did this by gluing four pieces of rough sawn timber (25 mm x 30 mm) together in a rectangle. We made it as close to the same dimensions as the hole we would cut as possible.
2. Draw A Template
To begin the Polyvision window installation process, you’ll need to make a template for the size of the hole that you need to cut out.
This is a bit complicated on this type of window, as there is a lip slightly wider than the hole that you need to cut and one slightly narrower. You need to cut a hole that is the dimensions of the widest metal lip after the main plastic frame around the edge.
The plastic frame will stay on the outside of the van, and all metal framing will be inside the van. Be sure not to make your template too big, you can always trim them a little more, but you can’t put wall back after you’ve removed it!
3. Cut The Support Beam If Necessary
Before you start to cut out the window, you want to remove the thick of metal support beam so that it doesn’t interfere with the jigsaw. The best method to do this is an angle grinder, but be careful you don’t cut all the way through to the outside panel of the van in a spot where your window won’t be.
We actually removed our support beam with a hacksaw as it was only attached by a small piece of welding at the top and bottom. This took an extra five minutes or so. But it was a lot safer than risking putting an angle grinder through the van wall by accident.
4. Stick On Your Template
Place your window template on the inside of your van. This is up to you where you wish to place your window in the van, but consider a couple of things before you begin.
- If you can avoid structural beams definitely do so. There are small supports across the large panel walls which are fine to remove, since you’re taking most of the panel out in place of a window anyway. However, you don’t want to touch the main structural support of the van itself.
- Consider what doors and other furniture you will have. After we installed our window at the foot of our bed, we realise that when when we open the sliding door, it will cover the window, and risk breaking it if the window is open at the same time the doors open.
- Try to be level. Easier said than done, in a curved piece of metal. But give yourself the best chance by installing your windows on a level driveway or street.
5. Draw Around The Polyvision Aero Window Template
Once you’ve position your window, draw around your cardboard template so there is a window transferred onto your insight panel where it will be.
Because you will be cutting from the outside in, you need to transfer this template from the inside to the outside of the van. You do this by drilling pilot holes along the line that you’ve drawn inside, and particularly around the corners.
Once you have four or five pilot holes on each corner and a couple along each straight you should be good to go.
6. Draw The Window On The Outside
Now that you have your pilot holes, play connect the dots to recreate your template on the outside of your van. You can use the cardboard template again to help you clean up the dots as well. The more accurate you are with the pilot holes on the inside, the easier this step will be.
7. Cutting The Van!
This is it – you can’t delay the scary part any longer!
How To Cut A Hole In Your Van
- Protect your paintwork from the jigsaw plate by masking taping over the jigsaw itself and the lines you’ll be cutting.
- Use a large drill bit (10mm+) to put a hole near one corner to fit the jigsaw blade into.
- Then its time to cut around the template you’ve drawn with a jigsaw.
- Take it slowly, line by line
- Be sure to start turning into the corners before you reach them or you risk making the window hole way too big.
- If there are two of you, its great to have someone on the inside to keep an eye on the template and shout if you go too off-track.
- As you finish each line, duct tape back over the cut on the inside to stop the cut-out falling and warping the van wall.
- Safety first: wear goggles & gloves.
If the hole isn’t big enough
- Test the window in the hole you’ve cut.
- Depending on how far off you are from it fitting (major props if it fits first time!) file down the edges with a hand file, angle grinder or taking the jigsaw round a second time.
- Careful to shave off bit by bit and don’t make it too big!
Tip: Using an angle grinder MELTS masking tape onto the van – peel this off before you start any filing or face a very painful job trying to get it off again.
8. File The Edges & Paint
Once the window fits in the hole that you’ve cut, file down any sharp edges and paint all exposed metal with a Hammerite paint. This prevents rusting.
9. Glue The Frame On
Using Gorrilla Glue, Sikaflex, or any other adhesive, glue the wooden frame you made earlier on the inside on the van around your newly cut out hole. Use clamps to keep it in place (and protect the outer paintwork of the van with cardboard or a second piece of wood).
///// Take a break and wait on the glue and paint to set.///////
9. Apply Sealant (Sikaflex 512) and fit the window.
Pipe a thick bead of sealant around the plastic lip of the window. Be generous here, you want it to squeeze out all the way around when you put the window in.
Then lift the window carefully into the hole, ensuring its the right way around. It helps to have one person outside pushing it in, and another on the inside to guide it into the gap and hold it in place.
10. Screw In The Polyvision Aero Window Brackets
Using quarter inch self tapping screws, screw the brackets into the metal lip of the window frame, with the other half of the bracket pulling against the wooden frame.
It took us a bit of time to figure this out, but once we got them the right way around it made sense.
There is also a specific order to screw in the brackets depending on the size of window you have. Check this out on the instructions before you begin.
The window doesn’t come with screws, so buy these in advance.
11. Clean & Leave To Set
As you screw each bracket, sealant should squeeze out the edges. wipe this off with a damp cloth, or an old credit card (gets a clean edge without risking scratching any paint work).
Then leave the window to set for 24-48 hours before driving anywhere or testing the waterproofing with a garden hose / bucket of water.
There you have it. One successfully installed Polyvision Aero Window.
Lessons We Learnt When Installing a Polyvision Aero Window
If you are putting windows / sky light or a hook up in your van conversion one of the first and scariest things to do is cut holes in your new van. The expression jump in at the deep end is too true. So here are some lessons we learnt that may help you feel more confident going into it.
1 – Spend the time getting the right tools together.
Once you get the right drill bit or tool it makes life SO much easier. We tried what felt like a 100 drill bits until we got the right size and type for our pilot holes. Jenna’s uncle gave us a flap disc for our angle grinder and it was alot faster to widen our window hole
2 – Measure, Measure, Measure.
If you’ve watched the windows installation process you’ll see we weren’t so good at getting the measurements 100% right first time but better smaller than larger.
3 – Silicon It Up
Put on tonnes and some more even if you think you have enough. We went to bed cheering victory after our first window only for it to rain and wake up with leaks. It was not fun cleaning the silicon and starting from scratch.
4 – Don’t forget about the wood frame.
When picking your window size remember you need to make sure there is enough space for the window and a wooden frame you need to go around it and support the frame. We wanted a lot of light so went as big as we could on the second window and were lucky to just fit the wood around it. I’m not sure we’d have been able to return the van with a massive hole on the outside.
5 – Screw Sizing
Get quarter inch self tapper screws. They didn’t come in our set and thanks to @adventuresinaubrey we knew we needed them to get the brackets in.
A bonus one – remember it will all work out well in the end. Jenna was about to punch me for the amount of times I said ‘we’re close’ but taking the time to do it right is important and eventually you’re done with it and have a shiny window to stare out off!
This blog contains affiliate links. If you make a purchase through them it won’t cost you any extra, but I may make a small commission.
CHECK OUT ALL THE VAN BUILD BLOGS HERE
