Well almost a year later, I am finally starting the install process.
Conversion windows are out. Donor sheet metal has been cut out of a van from a junk yard. Fitting that it was an HVAC van as that's what puts food on our table (albiet indirectly).
Plan is to trace out the patch needed, use a flare tool to crimp the patch piece, then spot weld from inside the van. Alternative idea is flush mount rivets. The Smyth Ute conversions rely heavily on these so they're a possibility too.
Taking the conversion windows out was shockingly easy. Also shocking is what hack job their cuts were on the inside.
From there, figure out placement for the flares and make the cut. Since the conversion windows made such a mess of the interior bracing we have some flexibility on where they will go. Will do a mock up of the bike storage + bed location before picking a final spot.
Will also see if the flare tool makes a big enough crimp that the flare would sit inset into it, much like it would with a factory window on a passenger van.
Edit: yes I am aware my garage is a mess. If I don't have 6 projects going on at once, I don't know what to do with myself.
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'06 EB 350, Advanced 4x4, 6.7 Cummins + Allison, 24" bubble top.
'05 Pleasure Way Excel TS V10, still boring and 2wd
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