Updating the updates1. Putting in fender washers to help hold up the paneling was an excellent move! Remove screw, slip on washer, reinsert screw... better than new. My concern with the thickness of the washer was unwarranted, as they appeared to be thinner than the paneling. When they were re-screwed, they easily held the panel tight; some of the washers bent as they went in (looking like mushroom tops), but that's a good thing, as they still grabbed the panel.
2. As for the windows, I put one in this past Saturday. Could have done the second, but I didn't want to chance my doing something stupid due to a growing sense of frustration. Frustration wasn't towards any one thing, but a slew of small things spread throughout the day. You know, normal day stuff. Anywho...
After having glued and pressed two 1/2" thick sheets of plywood together, I cut them to have a six inch frame; the interior holes were done to match the window, as they (the windows) weren't exactly square.
As my I-beams were riveted in place, I drilled next to the rivets so I knew which ones I had to drill out / remove. After the drilling, I cut and removed the I-beam with an oscillating saw. I then cut/split the I beam so that it could be folded as the above video shows: one portion for the horizontal, the other for the vertical.
With the e-track in the way, I wasn't able to screw the horizontal folds into the frame; I attached the vertical piece with basic screws. With the frame in place, I easily cut the panel with a sawzall.
Easily.
Before popping the window in, I went around the trim that would go against the van body with some butyl tape, and then went along the inside seam with some flexible silicon caulk; as you can see by picture
#3, I also filled any gaps with the caulk. I attached the window with self-sealing screws. Between the tape, caulk, and screws, this window should be pretty much water proofed!
I did screw up on one part. I had intended to pop the original panel back in place after cutting out the hole, and then trace the hole onto the panel so I could cut that... with window in place, I can then pop the panel back up and use basic floor trim as a window frame. That didn't happen, at least not with this window (making mental note to do it with the second). It isn't a hard mistake, I can always take measurements and go from there, it'll just take a little longer.
After Saturday night's steady rainfall, I checked on my window, and there were no leaks. Granted, it wasn't a hard downpour, but it was a steady rain... regardless of the type, if there were any leaks, they'd have manifested.
Tonight I am hoping to have the second window in. Frame's done, original panel is out, all I have to do is remove I-beams and essentially cut out siding. At the very least, I can remove I-beams today and install tomorrow, but this shouldn't take more than an hour.
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