How to make new window sills for a Panel van

Discussion in 'How To' started by Marc Mears, Apr 15, 2013.

  1. I have been asked how I made the sills for the widows so here it is-
    Making new window sills for the rear widows of a type 2 VW panel van
    I have fitted the middle window in and don’t have to old one as a template – but it is a simpler version of the rear.
    These window sills are for the panel van conversion – mine was a Danbury.
    For the middle window use the same 20mm x 37mm (40 will do) batten for the support and the actual sill you will have to make a template, but it does not require a chamfer putting on the edge
    Unlike the rear ones the middle window sill (the top bit) is screwed from underneath.
    The Rear Sills
    The simplest way to get a sill is to have a laminated top so its pre finished – I had some old laminate flooring left over, it was 12mm so I was lucky – the other way would be to go to a local carpet shop and see what they had in as left over from previous jobs, you may get some for nowt!
    Problem is most laminate is 8mm and engineered wood flooring is 14mm – but you can always pack it up or shave it down.
    The plan is for the driver’s side – so you will have to invert it for the passenger’s side.
    Once you have cut out the top you will have to route out a section from the underside – leave 8mm or so of the top, you will see on the body shell that there is a section protruding up, this is why you have to rebate the underside of the window sill.
    Once made, get your soft wood batten and cut to size, Align the softwood batten with the top edge of the bodywork, and self-tap with stainless steel screw through the body – 3no only – Now you will have to use you judgment on where to screw through – as they go through to the outside – but will not be seen as the sliding door cover, covers the screws.
    On the sliding door side I put mine at the top – but it did catch the top of the mechanism – so I cut the screws down – one at a time, and it runs free. You must insure that the screws go above the metal runner.
    Once in manipulate the new sill into place and fix with 3 no screws with cup washers.
    I silicone up the edge by the window on mine and it gave a good finish.
    Please Note
    These notes and drawing are for guidance only and you must check your sizes against your VW as they may differ, the plans are not to scale and using these plans and fitting instructions is solely your responsibility and carried out you your own risk, if you drill through the wrong place – it’s your fault for not looking and measuring up first.
    Apart from that I hope these will come in handy for you.
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    This is the middle window sill
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