How to Fit Windows in a Campervan , Step-by-Step Guide

How to Fit Windows in a Campervan , Step-by-Step Guide

Installing campervan windows is one of the biggest milestones in your self-build journey.
It transforms your van from a blank panel into a bright, livable space - and with the right tools, you can achieve a factory-quality finish yourself.

At Obsidian Leisure, we’ve fitted countless campervan windows using high-quality sealants, bonding kits, and glass panels.
Here’s our trusted method for fitting windows safely and professionally.

What You’ll Need

Before starting, gather everything you need to keep the job clean and efficient.

Tools:

  • Drill and metal-cutting jigsaw/ nibbler

  • Masking tape and marker pen

  • File or deburring tool

  • Panel wipe and microfibre cloth

  • Sealant gun and clamps (if required)

Materials:

  • Campervan window (bonded type or framed type)

  • Cutting template (supplied with most window kits)

  • Primer and bonding agent (e.g. Sika or Dinitrol kit)

  • Black trim edging (optional for neat finish)

  • Rust treatment and paint for bare edges

  • Gloves and eye protection

Obsidian Leisure stocks a range of bonding kits and sealants ideal for window installations - all with Amazon-fulfilled delivery.

Step 1: Choose Your Window Placement

Plan your window positions carefully before cutting.

Consider:

  • Bed area - for natural light and airflow

  • Kitchen area - ideal for sliding windows

  • Rear doors or side panels - for visibility and ventilation

Inside the van, mark where the frame ribs are - you’ll want to avoid cutting through any support beams.

Tip: Use masking tape to outline the cutting area - it protects paintwork and gives a clear cutting guide.

Step 2: Mark and Drill the Corners

  1. Use the template that came with your window kit.

  2. Tape it in place and double-check alignment from inside and outside.

  3. Drill pilot holes in each corner of the marked area using a 10mm drill bit - these will help guide your jigsaw blade.

Double-check your measurements before cutting. It’s easier to make the hole slightly smaller and adjust than to cut too large.

Step 3: Cut the Window Opening

Using a metal-cutting jigsaw blade, cut along your marked line, connecting the corner holes.
Take your time and let the blade do the work - don’t force it.

Once complete:

  • File down any sharp edges.

  • Treat bare metal with rust inhibitor or primer paint to prevent corrosion.

Leave to dry before bonding your glass.

Step 4: Prepare for Bonding

  1. Clean the panel surface and glass bonding area with panel wipe or isopropyl alcohol.

  2. Apply primer to both the glass edge and the van panel where adhesive will contact.

  3. Allow primer to dry according to the manufacturer’s instructions (usually 10–15 minutes).

Then, apply a continuous bead of polyurethane adhesive around the cut opening.

We recommend high-quality bonding products like SikaFlex or Dinitrol - both available through Obsidian Leisure.

Step 5: Fit the Window

  1. With the adhesive applied, carefully press the window into position.

  2. Apply gentle, even pressure around the edges to ensure full contact.

  3. Use window tape or temporary supports to hold the glass in place while curing (at least 4-6 hours).

If using rubber-trimmed framed windows, secure them using the inner fixing ring and screws instead of adhesive.

Step 6: Clean and Finish

Wipe away any excess sealant immediately using a clean cloth and panel wipe.
Fit your rubber trim or edge finishing strip for a clean, professional look.

Avoid washing the van or driving at high speeds for 24 hours while the adhesive fully cures.

Step 7: Check Your Seal

Once cured, test for any air or water leaks with a light water spray.
If needed, touch up any missed spots with a small bead of adhesive or sealant.

Properly fitted windows will be fully watertight, quiet, and give your camper a factory finish.

Extra Tips

  • Always cut from the inside out to follow the van’s internal profile.

  • Install windows on a dry, mild day (ideally 10-25°C).

  • Keep the glass in its packaging until ready to fit - to prevent scratches or contamination.

Why It’s Worth Doing Properly

Fitting your own windows saves money and adds huge value to your van conversion.
It gives you natural light, ventilation, and a real “camper” feel - ready for your next adventure.

At Obsidian Leisure, we’ve sourced and tested products that make DIY conversions easier, safer, and longer-lasting.
All are available through our store - fulfilled by Amazon for fast delivery and trusted quality.

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