🔧 How to install or replace a broken motorhome window?

Your camper van window (projectable, sliding, or fixed) is damaged? It may be necessary to completely replace it to ensure waterproofing, brightness, and comfort in your camper van. Here is a step-by-step guide to install a new window in your camper van or converted van safely, even in the case of cutting the sheet metal.

🔍 1. Remove the old camper van window

As part of a replacement, the first step is to carefully remove the existing window. Remove the screws, seals, and the interior frame. Once everything is disassembled, you should have a bare and clean sheet metal, free of glue, rust, or sealant residue.

💧 2. Protect the bodywork with adhesive tape

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

⚙️ 3. Prepare the cutting template

From the new camper van window you are going to install, create a template with the correct dimensions. The template should correspond to an opening equal to or larger than that of the old camper van window. Use stiff cardboard or thin plywood to ensure an accurate marking.

🪟 4. Mark and drill to facilitate cutting

Place your template on the sheet metal, then trace its outline with a marker. Next, drill passage holes in each corner: these holes will allow you to insert the jigsaw blade more easily and obtain clean cuts.

💡 Tip: if you need to enlarge an old camper van window hole, follow the same process while keeping the drillings clean.

🧼 5. Remove intermediate reinforcements (if present)

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

6. Cut the sheet metal cleanly

Follow the line traced by the template of your camper van window by cutting with a jigsaw equipped with a blade suitable for metal. Work slowly to maintain a clean and burr-free cut. Be careful of projections: wearing glasses and gloves is recommended.

7. Apply an anti-rust treatment

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

8. Apply the adhesive sealant for installation

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

9. Install the new camper van window and its frame

Position your new camper van window outside, then align the battens and the interior frame. Then screw from the interior frame to the window, without over-tightening. The assembly should be solid and waterproof, with no play or movement once the screws are tightened.

Tips for installing windows on your van

Tips for compensating the curvature of the sheet metal of vans

Your projectable window does not need to be curved to be installed on the wall of your van:

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

📌 10. Admire the result!

Your camper van window is now installed cleanly, with a precise cut, guaranteed waterproofing, and a professional finish.

You can replace the screen and mosquito net if necessary, and test the proper opening/closing of the window.

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

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

🛍️ Why trust VanLife Store?

Need a replacement compass, a sealing kit, or a new ready-to-install window? 👉 Find everything you need at Vanlife-Store.com and prepare for 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 (projectable window, sliding window, fixed window).

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

✅ A team at your service to guide you in your choices and answer your technical questions.