🔧 How to install or replace a broken Window in a motorhome?

🔍 1. Remove the old Window camper van window

As part of a replacement, the first step is to carefully remove the existing Window. Remove the screws, seals, and the inner counter frame. Once everything is dismantled, you should have a bare and clean metal sheet, free of glue, rust, or sealant residues.

💧 2. Protect the bodywork with adhesive tape

Before any cutting, apply masking tape around the cutting area formed by the recess of your Window camper van window. This helps preserve the paint and avoid any scratches or chips caused by the jigsaw blade. This is a often overlooked but essential step for a professional finish.

⚙️ 3. Prepare the cutting template

From the new Window camper van window you will install, create a template with the correct dimensions. The template must correspond to an opening equal to or larger than the old Window camper van window. Use rigid cardboard or thin plywood to ensure precise marking.

🪟 4. Mark and drill to facilitate cutting

Place your template on the metal sheet, then trace its outline with a marker. Next, drill entry holes at each corner: these holes will allow inserting the jigsaw blade more easily and obtain clean edges.

💡 Tip: if you need to widen an old Window camper van window hole (or fitted van), follow the same process while keeping the drillings clean.

🧼 5. Remove intermediate reinforcements (if present)

Sometimes metal reinforcements cross the cutting area. In this case, you can cut them with a grinder and remove them. These elements are not load-bearing but only anti-vibration, so their removal does not affect the overall structure.

6. Cut the metal sheet cleanly

Follow the line traced by the template of your Window camper van window by cutting with a jigsaw equipped with a blade suitable for metal. Work slowly to keep a clean and burr-free line. Beware of splinters: wearing goggles and gloves is recommended.

7. Apply rust treatment

Once the cutting is finished, treat the edges with a rust protection product (such as Ferose or Rustol). This will prevent future corrosion, especially on older vehicles or those exposed to the elements.

8. Apply adhesive sealant for installation

On the edges of the new opening, apply a regular bead of adhesive sealant. To fix the Window on the metal sheet, Sikaflex 265 is ideal. If you use battens, glue them with Sika 11-FC for a durable fix. Do not skimp on the amount to ensure waterproofing.

9. Install the new Window camper van window and its counter frame

Position your new Window camper van and fitted van window on the outside, then align the battens and the inner counter frame. Then screw from the counter frame to the Window without going through. The assembly must be solid and watertight, without play or movement once the screws are tightened.

Tips for installing Windows on your van

Tips to compensate for the curvature of van metal sheets

Your Push window does not need to be curved to be installed on your van wall:

• When the assembly composed of your metal sheet + your battens is slightly thicker than the distance (A) (on diagram 1 - which is the distance between the ends of your counter frame and the Window on the outside), the pressure exerted by the outer parts when screwed together will compensate for the curvature of the metal sheet. There usually remains a few millimeters between the metal sheet and the end of the Window, which is filled by the adhesive sealant
• The screw (ideally self-drilling - otherwise you will first need to create a hole with a drill) passes through the counter frame to the grooved part of the Window, without piercing it.
• Once tightened, the assembly must be perfectly immobile and compact
• The thickness of the batten can be as wide as you want! the essential thing is to have a screw going from the inner counter frame to the part inside the Window that solidifies the whole assembly!

📌 10. Admire the result!

Your Window camper van window is now installed neatly, with a precise cut, ensured waterproofing, and a professional finish.

You can put back the store and the mosquito net if necessary, and test the proper opening/closing of the Window.

Conclusion: a repaired Window camper van window means a more peaceful journey

Don't let a broken Window camper van window ruin your trips. By following these tips, you can diagnose and repair a faulty Window camper van or fitted van window yourself, whether it is sliding, projectable, or fixed.

🛍️ Why trust VanLife Store?

Need a replacement hinge, a sealing kit, or a new Window ready to install? 👉 Find everything you need on Vanlife-Store.com and prepare your next adventure with peace of mind.

At VanLife Store, we know how much your comfort depends on the reliability of your equipment. That's why we offer:

✅ A wide selection of Windows suitable for all types of vans and camper vans (Push window, sliding, fixed Window).

✅ Complete tutorials to guide you step by step in your repairs.

✅ A team ready to listen and guide you in your choices and answer your technical questions.