Okay, curtain time.
Following some input from people here, I both bought one of those handheld sewing machines as well as experimented with heat welding synthetics. The little sewing machine works okay but it won't penetrate more than a couple layers of fabric. I'm bad at sewing and was folding lazily. I found it was much faster (and, for me, cleaner) to heat weld the material. But instead of cutting with a hot knife, I found the way that works best for me to get a clean edge:
1) Lay the material out and mark it where you want it cut.
2) Put a straight edge over that line and cut with a razor knife.
3) WITHOUT MOVING the straight edge, run a butane torch along the line that's currently pinned under your straight edge.
Doing that keeps everything from fraying and leaves one very clean, straight line. Singing more of the material than the very edge leaves it clumpy/warped/cracking etc thus the importance of the straight edge.
I used "aurora" satin blackout curtains from Wal-mart. They're $20 per 84" panel but two panels was enough for every window in the van including the overcab. This material blocks out light MUCH better than the stock vinyl backed curtains, as seen here with one old and one new.
Seen from the inside in bright daylight. They almost work
too well, as it's dark in there unless I pull a curtain. But I planned for that with the layout of my snaps and they're actually much more modular than they appear. Also I painted those speakers gray as a bit of an accent while I was at it...
I did all the rear windows except this one, which I spray painted black because it's hidden from the interior and idgaf.
Overall these curtains are much easier to use. I hated those old vinyl ones - the stuck on the rods, the rods protruded... these are all recessed into the window, modular, able to open/close windows without fighting with curtains, and they totally block light. At night, with lights on, it's almost impossible to see from outside that there's light in there unless you get really close and peak into corners of windows.
Also I just think the van looks more
awesome with all the windows all blacked out!