Fitting bonded windows without fear

Before you pick up a jigsaw

Buy the window first and use the manufacturer's template. Never use the glass itself as a template. Check the inside of the panel for looms, braces and anything you would hate to cut through. Mark from both sides and compare.

If you are unsure about structure, stop and ask someone who has cut that model before. A wrong hole is expensive.

The sequence

1. Mark the aperture inside and out. Check twice against the template.
2. Drill starter holes at the corners with a step drill.
3. Cut with a jigsaw and a fine metal blade. Masking tape on the shoe protects paint. Support the offcut so it does not tear the panel on the last millimetre.
4. File the edge smooth, then etch-prime and seal. A raw cut edge will rust within a season in UK weather.
5. Dry fit every time. Bonding is not the moment for surprises.
6. Prime and bond with the correct activator and adhesive for your window kit. Clamp or tape for the full cure time the maker states.
7. Trim and hose-test the next day. Fix weepers now, not after the lining is in.

Weight and handling

A large bonded window is often around 10 to 14kg, and it sits high. Two of them change how the van feels on the road. Add them to the payload tracker as exterior items.

Common mistakes

Rushing the bond, skipping the primer, and forgetting to seal the cut edge. The adhesive is only as good as the prep. Give yourself a calm afternoon, not a squeezed hour before dark.

If water finds a path, it will. Hose-test before you trust the van in rain.

Figures in this guide are planning estimates. Confirm weights and prices against real products, and have gas and electrical habitation work signed off by a qualified person.