Putting Windows in a box truck?

[flying kurbmaster]

rv windows are not hard to install, I installed two on my kurbmaster along with four locker doors which are basically the same installation technique. I used a drill to get my jig saw started and cut them out using a jigsaw, that is a good suggestion to tape the outside where you are running your jigsaw to avoid scratching. I didn't have an inside flange on the windows or locker doors I bought so I used butyl tape and screwed them on from the outside. On the inside of the windows because there is a screw chase for the inside flange I made the flange out of wood and mated it to the window and sandwiched the interior wall, insulation and exterior wall. After the first year I found the butyl seeped black lines down the side of my van from the corner of the windows, so I cut the butyl flush and ran a clean beed of sealant all around, one that didn't seep and held the butyl from seeping. Five years on and they haven't seeped since, windows don't leak, they look great.

 

[flying kurbmaster]

rv windows are not hard to install, I installed two on my kurbmaster along with four locker doors which are basically the same installation technique. I used a drill to get my jig saw started and cut them out using a jigsaw, that is a good suggestion to tape the outside where you are running your jigsaw to avoid scratching. I didn't have an inside flange on the windows or locker doors I bought so I used butyl tape and screwed them on from the outside. On the inside of the windows because there is a screw chase for the inside flange I made the flange out of wood and mated it to the window and sandwiched the interior wall, insulation and exterior wall. After the first year I found the butyl seeped black lines down the side of my van from the corner of the windows, so I cut the butyl flush and ran a clean beed of sealant all around, one that didn't seep and held the butyl from seeping. Five years on and they haven't seeped since, windows don't leak, they look great.
ps I tend to agree with the rest of them a lot of windows present challenges as do too few.

 

[speedhighway46]

OK, just spitballing here.

How easy would it be to put Windows in a box truck? I see a lot more around for what I can afford. I could delay installing the windows while I still need stealth, here in town. Then install the windows once I get out in the boonies. I definitely know I don't want the  vehicle I live in to be like a cave.

Hello Grant:

My wife and have spent the last five years converting a Peterbilt 379 road tractor into a motorhome; its all done. One of the major tasks was window installation.

We purchased a new 16' Morgan box van to mount on the extended framerails of the truck. It came to us as a standard cargo van, empty and no rear doors. After finalizing the layout, we next determined window location. We purchased "new old stock" windows for around $25 each from various rv surplus dealers in White Pigeon, MI. I was then able to determine the each cutout size for each window.

Window location was marked on the outside of the box. Because all the windows crossed vertical supports, I added "headers" along each side of the box extending the entire 16' length. I used 1/8"x4" flat stock, bolted directly to the vertical supports inside the box. I then cut the opening for the windows one at a time using a cordless Milwaukee saber saw and a 18 tooth blade. Slow and steady when cutting to avoid "saw jumping", all went well. The windows were riveted in place to match the rivet pattern on the box and the tractor. We mounted a total of six windows.

Questions, let me know. Hope this helps.

Speed Gray, K8SG

 

[masterplumber]

Cool rig, I love the Pete 379s. Not sure if you have enough engine for 22,000 lbs though. ; )

 

[speedhighway46]

Cool rig, I love the Pete 379s. Not sure if you have enough engine for 22,000 lbs though. ; )

Thanks for looking. This was my first post here; great site!

 

[LoupGarou]

Do you have a build blog on the truck and the Morgan Cargo Body?

 

[highdesertranger]

that is so cool, I love it. what's the standard height of those boxes? what kind of mileage you get with that? if you don't mind what does a box like that run approx.? oh yeah welcome to the best RV/van/whatever forum on the net. highdesertranger

 

[Fabber McGee]

If you're concerned about structural rigidity, run a piece of Hat Channel or a Z vertically between the windows. Floor to ceiling, or between horizontal members if you have them. They are available in a large number of sizes, or any sheet metal shop can custom fold whatever you want. Click on the images to expand them.

 

[speedhighway46]

that is so cool,  I love it.  what's the standard height of those boxes?  what kind of mileage you get with that?  if you don't mind what does a box like that run approx.?  oh yeah welcome to the best RV/van/whatever forum on the net.  highdesertranger

The Morgan box we purchased was special order and made to our specifications. This included upcharge for hard maple floor, stainless steel from and rear frames and corners, stainless steel painted rivets, and custom height.

When we first visualized the finished motorhome as it would end up, it was important to us to keep the "line" of the roof of the box an extension of the sleeper height. This meant that the height of the box was shorter than a normal box. Inside the height is 6' 5". Esthetically it turned out just how we want. The overall motorhome has very good proportions and balance (for a truck!). Because the box was special order and took abt 10 weeks to arrive. 

The cost of the box included mounting to the frame rails, fabrication of the rear bumper/tow bar, fabrication of the folding aluminum steps, purchase and mounting of the three stainless steel side boxes, extending the frame rails six feet aft of the rear drivers and fabrication of two fender brackets. Total cost was $12,000.

If you want to save some bucks, I would look at finding a used box; they are dirt cheap. My wife wanted "new and fresh" so that's why we spent the big money for a new one. For a used box check some places like Marysville Truck Equipment, Marysville, MI 810-364-0730, or on line using ebay or the many upfitters who have sites. These used boxes are stacked up like cordwood; just inspect before you buy. There are nice ones, and there is junk.

I do not have a blog showing the construction; sorry.

Mileage as I bought the truck was abt 7 mpg; after I dropped the front drivers it jumped up to 11-12 mpg; I have gotten as high as 14. Pretty happy abt that.

Thanks for all the replies to my post.

Speed Gray, K8SG
Grand Rapids, MI

 

[highdesertranger]

thanks for the reply. you have a really nice rig. highdesertranger

 

[IGBT]

Thanks for looking. This was my first post here; great site!

I have rig envy now.   I thought we were doing good at 17,000 pounds and 10mpg, but to see someone getting 11 to 14mpg on a 22,000 pound rig that could also tow the space shuttle...