You'll have 45-ish lineal inches to cut, but that's not so far in such thin metal. 12" is a large enough diameter that a hacksaw can make that curve. or, cut a 4" diameter hole in the middle using coarser methods, cut the first inch with the bare blade (wear gloves, I show this in red) and then put the bow of the hacksaw through that hole. Either use the kind of hacksaw where part of the blade extends beyond the tool (and don't kink it). Start it by drilling a hole well inboard of the edge.
That's cheap/easy.įrom there, I would use hand tools, such as a VERY fine tooth hacksaw, working carefully. If you bodge it up, peel the tape, lay new tape and mark again. First, as JACK advises, lay down masking tape and accurately mark the circle precisely on the tape. With that in mind, I would tend to go old-school. Almost any power tool will tend to do that, as will many hand tools. The #1 problem will be distorting the outside of the circle and creating yourself either ugliness or a need to do body work and paint. The van metal is VERY thin - its strength comes from being stamped in a curve, not thickness. If your window depends on being a true circle in a flat medium, and not a Pringles chip, then the window will not fit. The shape is akin to a Pringles potato chip. If it wasn't curved it would go "waggle-waggle" as you drove down the road. The curve gives it a great deal of strength. A regular grinder is 90 degrees out so would not work the same.Ī circle would require the van side be flat. If you had a Dremel-style cutoff wheel, then the same basic idea would work to hold your tool on the circle. Also have an assistant on the outside who can watch what you can't see, and kill the power if there are problems.īolt the radius-wood to the center-hole of your planned-hole, and work your way around taking your time on the cut. Use eye protection because there will be sparks.
Use ear protection because its going to be awful loud in the tin box. I would work from inside the van, so you're not dragging the jigsaw around the exterior paintwork. Secure the other end to your jigsaw so that it sticks out to one side but doesn't interfere with operation. Use a short length of scrap wood or metal, and drill a hole in one end. Presumably you've removed any lining already and have clear access.ĭrill a small entry hole on the circumference, just large enough for your jigsaw blade to start. Start by drilling a center hole in the van, and carefully measure inside and out to make sure you're clearing any framing members or reinforcements. A sabre-saw is not suitable for this approach. You'll need a fine-tooth metal cutting blade, and maybe several. Caravan roof vents are the perfect solution for extra light and ventilation (especially on hot summer days!).If the only tool you have is a jigsaw, then make a radius guide. Our roof vents come in various sizes and have a number of different features such as lights, fly screen, levers and black out screens. Our thermal blinds can be quickly attached via suction cups, too. We have a range of curtains with rails custom designed to fit campervans, including blackout curtains. We supply adhesive bonding kits for easy installation - the same technique used in factory installation.
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