Couple of shots from yesterday evening. I started by measuring everything a few times, and then made a template of the INSIDE measurements of the window. By happy fortune, this matched the dimensions supplied above - 180mm from the front door trim strip, 150mm from the rear corner and 35mm from the gutter. Note the pretty M&S crème brulee pot which produced the radius I needed for the corners. I had already used a compass, but this was much easier, and matched the radius of the corner perfectly. The areas for cutting were then masked up and marked ready for cutting.
windowinstall1.jpg windowinstall2.jpg windowinstall3.jpg
 
OK here we go. Using a tape measure and pencil, make a few marks at the 180mm from the front, 150mm from the back and 50mm (not 35 as per my previous post) from the bottom and top.
Run strips of masking tape to form the rough ouline of the cut - you can see the pencil marks through the tape which will guide you.
DSC_0953.JPG DSC_0954.JPG
 
Now using the pencil, join up the marks to form a box outline, and use your cardboard template (or ramekin) for the corners. You should end up with a pencil outline of the shape of the cut. Don't use a thick felt tip - you want to be as exact as possible.DSC_0955.JPG
Put plenty of masking tape outside the shape to prevent the jig saw marking the paint. Assemble all the tools: DSC_0932.JPG and empty out all the crap/useful stuff from the inside,DSC_0964.JPG seat bases, carpets, everything. Everything within 15 feet will get covered in fine alloy dust when you cut with the grinder - including you. If you don't wear glasses, safety glasses are a very good idea.
 
Now you're ready to make the first cuts with the grinder - use a 1mm disc. DSC_0958.JPG
If you have any doubts, measure everything again, and use you cardboard template to make sure the pencil marks are accurate.
Cut away! The grinder will cut through the panel like a knife through butter, until you have your first four straight cuts. If needs be you can finish the cuts through the strengthening rib on the inside, or use a hacksaw blade from the outside. You should end up with this: DSC_0930.JPG. This was my first side, where I used a thick marker. Better to use a pencil and cut just outside the pencil marks. A mm or two out won't matter, the lip on the window frame will hide any small errors. To finish the cut, use a jig saw. I pushed it through a wider area of the grinder cut and guided it to the corners, where I followed the outside of the pencil marks: DSC_0960.JPG. All of a sudden you will be looking at a large hole: DSC_0966.JPG, hopefully not with my missus in it!
 
Now you're ready to trial fit the window. You will likely have to fettle/trim the hole before it fits well. I used a grinding stone on a drill, which was pretty quick. Once the window fits nicely, tidy up the cut edges. Ed China had a special tool for this, I used a half round bastard: DSC_0942.JPG. Remove the remains of the masking tape. Hold the window in place and drill the holes for the rivets (4mm)DSC_0962.JPG . Place a rivet in the hole as you drill, this will stop the window moving as you work around the window. I found it best to work in a clockwise direction, starting at the bottom. DSC_0968.JPG. Now take the rivets out and pop the window onto a piece of the cardboard packing, ready for a bead of mastic: DSC_0946.JPG. I used this stuff from Screwfix, based on the reviews on the website. I had considered foam tape, but I think this should seal really well. Run a 5mm bead around the window, where is will contact the frame. Get some old rags or paper towel ready to wipe off the excess.
 
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Nearly there! Carefully place the window back in position and insert all the rivets again. Now "just" work your way around the window, nipping up the rivets. If you haven't used a riveter before, remember to pull slightly outwards as you make the final squeeze of the trigger, to prevent the riveter marking the paint on the frame.DSC_0947.JPG. You may need to get your helper to push out the panel against the window frame to get a good tight seal. My panels were pretty good. Now get the rag/paper towel and wipe away any excess mastic from where it has been squeezed out around the frame. Don't panic if you get some on the glass/frame, Screwfix also sell mastic remover. You will hopefully end up with this: DSC_0949.JPG
To finish off this "deluxe" kit, there is a piece of rubber trip to cover the rivets. Find the middle part of the trim and start working it into place from the middle of the window at the top: DSC_0969.JPG
I found I could just squeeze and push it into place, except at the corners, where I had to put the outer lip into the frame, and force the inner lip in with my thumbnail. My missus used a spork. The trim is overlong, so where it meets at the bottom/middle of the frame, cut both sides at 45 degrees so that they meet to fill the gap. Congratulations! Stand back and admire your work.
 
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Looks good, if you don't mind me asking how much are the kits? And have you spoken to your insurance people yet. I would like to do mine but it's a worry that the insurance vultures would start rubbing their hands, it seems they want to get their hands in your pocket if you paint the ash tray a different color.
 
The kit was £179.16 with tax. Haven't spoken to the insurance people yet, but I have changed from an estate to a pickup in the past, which only incurred an admin fee.
 
Looks like they've gone in really neatly. Your wife looks like a very kindly, friendly lady too!
 
Very straight forward for someone to follow after a forum search for window installation. Bet that's made a world of difference in the back. :)
 
Thanks for all the kind comments guys, much appreciated. As for my wife being friendly and kindly - we both had a good laugh , thank you.
 
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