How to install windows into a VW Transporter T5, step by step guide

Welcome to my step by step guide on how to change your windows in a Transporter T5. This is a 2011 model.

I will also list in here a step by step guide as well as things to be aware of and watch out for.

Make sure you have all the correct materials and tools before starting. In the video (if you pause it) will be a list of everything we used/you may need, Ensure you also have enough protective covering for when you begin cutting the metal. You will need to cover the inside when you are grinding and also the outside when you are nibbling. Both are extremely messy and can cause paint damage.

Now that you have everything you need and the van is prepped, we can get started.

First, un do the ply on the panel. Next, mask up the area on the struts you are going to angle grind off. Make sure its big enough for the nibblers to fit through. Also make sure it's flat at the bottom, don't leave a lip on it. angle grind those bits off. Next you are going to put a hole in each corner, using a drill. Then using a bigger bit, make those holes big enough for the nibblers to slide in and out of. Next you are going to draw the lines on the outside of the van, linking the holes. You are now ready to cut the hole. Using the nibblers (put your goggles on!) start cutting following the lines you drew. On your last cut, ensure you put the suction pad on the panel and get someone else to hold it, so it doesn't fall and damage/hurt anyone, or more importantly, your van!!! :) From the inside, you will need to cut away the remaining metal border. use the inside skin, as a border and lean the nibblers on it, as you cut. You may want to see what I mean by this by looking at the video. Now using a sander, file the edges flat. Now depending on whether you have pinch weld, you will have to Stanley this bit out. (I didn't have to) You should also rust proof the edge of your cuts at this point. I didn't do this as the product didn't show up. I may regret this down the line. So I recommend to do it. Use a thin nozzle and some window adhesive. Apply a bead of adhesive between the two skins of metal all the way round the window opening. Too much will just squirt out and be messy. Again this is your choice, I chose not to. Time to knock on your edge trim. Before you do, ensure you manipulate the two skins as close together as possible for the edge trim to fit. You may need a rubber mallet to knock on. Use a panel wipe to clean the edges, ready for priming. Using a clean felt applicator, apply your primer. Ensure to cover the correct area, putting enough on. Now you need to check the flushness of the window by offering it up (whilst on suction pads) while someone else checks inside for any gaps/daylight. You need to slightly knock the body work in place until it is flush. Now with a pencil mark up the inside line, for the glass activator to stop at. Now apply your glass activator, do not build up on layers of this. It will cause the vacuum effect, and you will experience problems later. once clean wipe of this product. now stick two lengths of non stretch tape (leave on roof) while you apply the all important bonding gear/adhesive. On the passenger side, start just below the top right corner and continue clockwise, finish off by feathering outside the start point so no water can get in. Using two suction handles lift the window into place and press firmly onto the adhesive. You will have time to move the glass around a bit to get it in exactly the right place.
Ensure the gap at top and bottom is roughly the same using your fingertips as a gauge. Once happy with the position, stick the tape straps down to stop the window sliding. Now press evenly all around the window. We used extra support by bungee strapping the glass to the inside of the van.

The vehicle should be safe to drive away in about 90 minutes.
In colder winter temperatures it is advisable to leave more time for adhesive to set. Once completely dry I would recommend giving it a clean and testing the window doesn't leak, pour some windows over the top.

I hope this has helped someone, no need to pay silly money to have them fitted. Do it your self! This was our first window which work wise to 4 hours. I think we can do it in, 2.5/3 hours next time.

Please like if it helped and sub for more camper conversion jobs coming. Thanks for watching.

I'M ALIAS

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