Mercedes Sprinter Van Conversion - Windows
Okay, before we jump into the actual installing of these windows. It may seem a bit strange to have Sprinter Van content on a bicycle fabrication website. However, the two go more hand in hand than you’d think. In fact, I recently just returned from the MADE.bike show in Portland and in the parking lot you’d think it was Adventure Van Expo. Anyways, my framebuilding business went absolutely to the moon during CoVID. A lot more people had free time and there was a huge influx of hobby builders looking for moderately priced and quality tooling to support that. For me, my business only makes sense with scale otherwise there are too many other conflicting personal and financial priorities for me to balance. So as that demand started to fade out a bit in 2022 I decided it was time to pull back a little bit and take on a project for myself. It would also afford me an opportunity to learn something new and allow me to take a break from the grind of working a full time job and running bikes parts until 1-2am most nights.
Aside from wanting to try something different for a bit, I was also looking for something a bit more versatile than our current overland camping setup. We’ve spent the weekends of the last 5 years roaming about the west coast in our 4Runner with a roof top tent, and while we loved it, it was starting to become a hassle packing that up, setting up the tent and getting the dogs and everyone situated up in there at night. BTW, if you are in the market for a Roof Top Tent, get a hardshell version instead. A soft-shell is definitely cheaper, but it’s not worth the extra time and hassle to setup.
If I were to boil down why the switch from a 4Runner to a 4x4 Sprinter, it would be primarily due to the unique advantages that the Sprinter offers. While the 4Runner may have a rugged appeal and off-road capabilities, the 4x4 Sprinter provides a whole new level of versatility. Its spacious interior can be easily converted into a camper van, making it perfect for long road trips or extended adventures. Additionally, the Sprinter's tall roof allows for standing room, enhancing comfort during extended stays. Furthermore, the Sprinter's strong engine and customizable options allow for various modifications, making it adaptable for different needs and preferences. Lastly, the Sprinter provides ample cargo space, enabling the possibility of carrying extra gear or equipment for any adventure. Overall, the 4x4 Sprinter offers a combination of off-road capability, versatility, and spaciousness, making it a tempting choice for those seeking the ultimate adventure vehicle.
Anyways, we went for it. We sold the 4Runner at peak CoVID prices and bought a 2022 Sprinter 4x4. Looking back I wish we would have spent a little more time reviewing the various dealer codes and purchasing options, but we ended up with a complete stripped 4x4 Sprinter Cargo Van. And with that purchase it was the catalyst that started the spiral into a lot more work than I could have ever imagined. Early on I knew I wanted to document the build process in video format, to be able to look back and follow along the steps, methods and order of our van conversion. Little did I know I’d enjoy that part almost as much as the conversion itself. We definitely started off a little rough as you will see in the video below. There wasn’t much of a plan, the audio wasn’t that great, I was a little awkward on camera & not as much research and time was involved.
For the very first project we choose to install windows in the middle of our cargo van. Looking back at all the available options CR Laurence is still near the top of our list. However, I think I’d do it a bit different now. Back then I was terrified of bonding in windows with Urethane so I wanted something that could be installed without that step. That’s the beauty of the CR Laurence windows is they are a gasket with a mechanical trim ring on the inside. This means no drilling and no permanent attachment. However, there’s a lot of material on the internet about the questionable lifting mechanism for their awning windows. These things can break and I must say they don’t inspire confidence when we use them. A year in now ours are still fully functional though and we just take our time to open and close them with care each time we use them.
Anyways, if I were to do this again, I would still probably use the CR Laurence on the passengers side, but then a slider type window on the drivers side, this is mostly because we plan to have a seat in that location in our build and I think it would be great for that person to be able to ope the window while driving. I still might end up doing this, but for now I’m happy with what I have. Let’s jump into how we made this happen:
Tools and Materials Needed
32 TPI Blades (we changed blades for each window cutout)
Rustoleum Auto Primer - We switched to Rust Bullet in our later videos
Air Compressor we have (way overkill as you only need 1.13cfm for the 529 Airsaw, but we love it. [** NOTE: Be sure to check specific Airsaw/Compressor cfm requirements if you are using something different]) - https://tinyurl.com/59yxzr3h
Basic Steps:
Mark the location of the window on the van.
Drill a pilot hole large enough for the blade.
Use the air saw to cut out the hole, starting at the pilot hole and working your way around.
Use the angle grinder and diamond file to clean up the edges of the hole.
Paint the edges of the hole.
Install the window in the hole.
Screw the window in place.
Test the window to make sure it is watertight.
Safety Tips
Always wear safety glasses when cutting metal.
Use a sharp blade to reduce the risk of kickback.
Be aware of your surroundings and make sure there are no people or objects in the way of the blade.
Dispose of metal scraps properly.
If you’d like to see the entire rundown of everything we did you can also check the video below. Thank you for stopping by!
