That could have gone better....
I spent 4 hours prepping and measuring the last window panel and surface for replacement. Then I spent 9 hours test fitting, modifying clamps, reinforcing the wall, jacked up the opposite side of the van and deflated the tires on the install side to tilt the van more parallel to the garage wall, ect. Everything I could to make the install go smoothly. This is the last panel and I can’t F it up... everything lined up nice. Only thing I was lacking was another set of hands to apply and tighten clamps while I held the panel in place. I'm stubborn and decided to attempt it anyway.
While looking up at the long lateral clamps above my head one came loose and cracked me in the face. (after that I welded a cross bar to keep them togeather) There was no blood so I kept working. Had a black eye the following day - but that’s not the worst part.
At one point while trying to hold the panel with one hand (its 44"x21.5") and apply / tighten clamps with the other, the panel slipped and I pushed it back into place. What I didn’t realize until about the time the glue was set up and ready to unclamp is (work time from mixing to cure is 40-50 minutes). When I pushed the panel up, I overlapped it with the existing panel next to it by about 1/16th of an inch. Creating a not totally flat panel :-( DOH!
To make matters worse, I couldn’t locate my blowtorch. How does one loose a blow torch?!?!?! with no heat, I couldn’t even remove the panel before it fully cured (4-5 hours) and homeDeblow had already closed.
Will have to reprep, refit, and retry.
Removing the panel was a bit tricky. First I cut out the middle section of the panel to reduce the amount of metal acting as a heat sink and make prying easier.
I started at one corner and applied heat via a torch running MAP gas, and worked the panel off by prying with a flat bar. That worked pretty well.
Then I heated the glue with a torch running propane and used a scrapper to remove most of the glue, then hit it with a DA to remove any leftover residue….. OK -Back where I started…
I obtained more adhesive last night and my brother came over to help install…..while cutting the new panel my Nibbler broke. The shaft inside it sheared off. …..Really?! Just can’t win. Going to attempt it again on Thursday…..