General woodworking question, give me your opinion please!

[evy]

Hi everybody,

I have a situation and I need advice...

Here's the basic info, I'm working on my inside panels (of the outside walls) I have to cutout the window openings, I can't remove the window's inside frame because they were designed for a 1.5" thick installation, the total thickness once I've added the inside panel will be around 2.25"-2.5"
In other words the panels won't be sandwitched inside the window's frame, I will be cutting an opening and it will fit around the window's inside frame.

Here's my question :
How do you trace the window's exact size on the back off my panel??
Is there a trick that I could use to do this?

I can open the bottom of the window and trace the opening but again I want to trace the outside of the frame.

When looking at the pictures, the panels resting on the seats are the ones I'll be cutting.

[evy]

As of now I will simply be measuring the window's frame from a reference point.
But that's less precise compared to tracing something...

[boywonder]

...a bit tricky..... but here are two ways....

1. Cut the hole in the panel rough/undersize......say by 2" all the way around. Then place the panel in place and trace the frame from the backside with a short pencil. Remove panel and cut to the pencil line.

2. Do the above then jig saw close to the pencil line like 1/4" and then screw the panel in place and use a bottom bearing router bit (or a laminate trimmer bit if the ply is thin) with a router to make an exact cut out on the plywood. Use a small router or better yet a laminate trimmer...the smaller the tool the better. You need to carefully set the cutter depth..you only want the bearing on the window trim. Too low and you will gouge the window trim too high and the bearing may end up between the panel and the window trim making a goofy-looking hole that is too big.

[rallypanam]

Not entirely sure I understand, but I think you can take off the inner window bezel thing and use to trace.

[boywonder]

Here is another question.....

What will make the new thickness go up by 3/4"-1"??

Your plywood should be rather thin.....like 1/8" or 1/4"

Also, I would remove the inside trim around the window, it's likely designed to accommodate different thickness walls; you may be able to trim the plywood with the window trim.

I would try really hard to trim the ply with the window trim...

Are you sure there isn't room for the ply behind the trim? I realize that you mentioned that it's designed for 1.5" thickness walls....how thick is the present install?

[evy]

Originally Posted by boywonder

Here is another question.....

What will make the new thickness go up by 3/4"-1"??

Your plywood should be rather thin.....like 1/8" or 1/4"

Also, I would remove the inside trim around the window, it's likely designed to accommodate different thickness walls; you may be able to trim the plywood with the window trim.

I would try really hard to trim the ply with the window trim...

Are you sure there isn't room for the ply behind the trim? I realize that you mentioned that it's designed for 1.5" thickness walls....how thick is the present install?

I'm very sure, the windows are installed and sealed, I can't remove the inside trim.

Right now the thickness is almost 2" and I'm adding a 3/8" thick plywood.

[evy]

Never mind guys, I went with taking very precise measurements with a reference point (from the top and the side) I always work with feet/inches but in this case I used millimeters

I used a window trim from an unused window to trace the corners (they have the same rounded corners)

Then I used my jigsaw very slowly, I will do the same on the other side.

[saline]

Nice work!
I must admit that making the interior panels on my van have taken me a long time. I still haven't figured out how best to trim out the windows.

[boywonder]

Nice Job!!

[gcvt]

Wow, nicely done!