HowTo ·

Popping Pills: How to Cut and Install Your Van Bunk Windows

Hey everybody, Matt here for AVC and welcome back to AVC Chronicles!

Today, we're tackling the installation of those popular "pill" or "bunk" windows. While we've installed tons of windows, getting this specific style right can be tricky. Over-tightening can cause little ripples along the bottom of the window, affecting the look of your van's metal. We'll show you how to get a clean, professional fit.

A quick shout-out to the YouTube channel Professional Piddler—they have a great video, and we even picked up a few tips from them! Go give them a subscribe.

Step 1: Prep and Template 📏

Before you mark your cutout, you may need to remove the internal metal ribs. We use an oscillating multi-tool for this step (check our other window videos for a detailed tutorial).

  1. Determine Placement: We like to place our bunk windows as high in the van and as far back as possible. This positions them perfectly for a bed or lounge area. Place the template right up against the pinch weld at the top and back.

  2. Create Your Cut Line: At AVC, we use our foam window frames as the template. If you don't have one, you can make a template from the cardboard box your window came in.

  3. Trace the Line: Place the window frame/template where you want the window to sit. Take a Sharpie and hold it flat against the edge of the frame/template. Trace the entire shape onto the van wall. This intentional offset (the thickness of the Sharpie) gives you the perfect clearance for the window's outer ring.

  4. Double-Check: Before you cut, use a separate cutout template (if you have one) or re-measure to confirm your marked shape is correct. Measure twice, cut once!

Step 2: Cutting the Metal 🪚

We've used shears and nibblers in the past, but for this cornered application, they can ripple the metal. We prefer to cut from the inside to avoid taping up the entire exterior.

  1. Protect the Paint: Use painter's tape to cover the pinch weld and the door rail to protect your paint from hot metal shards.

  2. Choose Your Tool:

    • Pro Method: We use an Astro Air Saber Saw (requires an air compressor). This allows us to cut from the inside, which is cleaner and easier.

    • DIY Method: Use a jigsaw from the outside. You will need to drill pilot holes around the inside corners to follow your line from the exterior.

  3. Start Cutting:

    • Punch a starter hole in the field near the bottom of your marked shape.

    • Have a second person secure the metal panel from the outside as you cut. This prevents the metal from flopping, scratching the van, or falling onto the ground.

    • Cut out the shape, following your Sharpie line carefully.

Step 3: Prep, Test Fit, and Prime 🧪

  1. Prep the Window: With the window on the bench, use a 1/8-inch drill bit to pre-drill the pilot holes around the frame. This makes it easier to set the screws later.

  2. Start the Screws: Set all of your screws into the frame lightly with an impact gun, then immediately remove them. This is just to test the threads for a smoother final install.

  3. Test Fit: Place the window into the cutout. It should be a tight fit, which is good.

  4. Tweak the Corners: If the window is too tight (especially in the corners), use a flap wheel on a grinder (or a hand file) to carefully remove a small amount of material from the tight spots. Repeat the test fit until the window slides in.

  5. Prime: Once the fit is successful, remove the window and prime all raw metal edges immediately to prevent rust. Check the outside of the van for any primer drips and wipe them clean.

Step 4: Final Install and Screen 🔩

  1. Install the Window: Have your helper hold the window firmly in place from the outside to provide back pressure. Place the trim ring on the inside.

  2. Hand Tighten: Use a standard hand Phillips screwdriver to set the screws. DO NOT use an impact gun! Over-tightening with an impact gun is what causes the visible rippling along the bottom edge of the metal. Hand tightening gives you control for a cleaner exterior look.

  3. Install the Screen: The window screen is typically removed for install. Slide it back into the groove inside the window frame. The last two clips on the back hold the screen in place. Use your screwdriver to add tension to these clips to prevent the screen from rattling while driving.

With that, your window installation is complete! Thanks for reading!

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