Fitting Instructions
Mat and Dan recommend that you ‘Make yourself a brew and make a plan’.
You will find a complimentary Yorkshire Tea Bag and a biscuit. We strongly advise you to brew up and find yourself a quiet to spot to have a read and make a plan for your window fitting job.
Go on off you go, brew up!
If you are sitting comfortably, then we will begin.
Firstly, thank you for buying a quality Repmac product. We know that you will be happy with your choice and we endeavour to offer some guidance and tips in regard to the fitting process.
Now the boring but essential bit. We cannot accept any responsibility for damage to your vehicle, the window or others from using this guide. By reading on, you are accepting full responsibility for the job in hand and accept that this fitting guide is offered to you purely for advice and is not a comprehensive instruction for fitting our products to every vehicle or situation. Please wear suitable personal protective equipment and take extra care when using power tools or ladders.
Repmac products are designed to be fitted by enthusiasts and DIY users with prior knowledge of the tools and processes required. We will try to help you as much as we can, but if you are unsure then please seek some professional help.
Let’s talk about the preparation. You will need at least the following tools and equipment in order to fit any of our windows:-
Wide low tack masking tape
Fine nibbed marker pen
Jigsaw and suitable blade
Drill and HSS Drill Bit.
Metal File and/or Emery Paper.
Methylated Spirit / Panel wipe or similar product to use a surface degreaser.
An appropriate adhesive sealant
Sealant Gun
Cleaning Wipes
Glazing tape or strong masking tape.
Tight fitting Latex Gloves.
Ladder or Step-up if needed.
PORTHOLE FITTING GUIDE
The correct positioning of your Repmac Porthole is very important. This product is designed to be fitted on any flat panel on the side or rear of your vehicle. This window must not be used on the roof of a vehicle. Before cutting any panel please ensure that you have carefully inspected inside the vehicle to make sure that there are no structural components, cables or other obstructions.
If you need to check if the desired fitting location is flat then we recommend using a spirit level or straight edge as close to the size of the window as possible. Place this on the side of the vehicle in the desired location, if it does not sit flat then the panel is not flat and the location may not be suitable to fit the Porthole. The most likely curvature of a vehicle is vertically from top to bottom, so please check this carefully.
Once you have chosen the fitting position then use the cardboard template provided. We recommend checking that you are completely happy with the template by placing it on the rear of your window.
Using a wide low tack masking tape to protect the vehicles paintwork is recommended. With a circular window such as the Repmac porthole this will involve using several shorter lengths of masking tape to create the circular protection that you need.
Position the cardboard template and secure with a few pieces of masking tape. Draw around the template with a suitable fine nibbed marker pen. Remove the template and check your line carefully.
As all good tradesmen say ‘measure twice cut once’. Check and double check before you attack your beloved vehicle with any kind of cutting implement.
Once you are happy with your marking out, you need to select an appropriate cutting tool. We recommend a Jigsaw with a brand new blade suitable for the material that you are cutting. Most of the time this will be thin sheetmetal if you are cutting out a panel van or similar. You need to use a fine tipped metal cutting blade suitable for the application. If in doubt ask the supplier or read carefully on the packet.
Ensure that there is sufficient masking tape to the outside of the cut line. The jigsaw bed will vibrate and rub on the paint when you cut and the masking tape will prevent scratches to the vehicle paintwork.
You will need a HSS drill bit (High Speed Steel) to drill a hole big enough to pass the jigsaw blade through. This will vary depending on which blade you choose for the jigsaw. It it a good idea to drill a smaller hole first and then use the bigger drill bit to open up the hole to the desired size.
With the appropriate sized drill bit, drill a hole on the inside of your marked line with your drilled hole touching or very close to the line. Don’t push too hard and let the drill bit do the work to avoid denting the panel.
You’re now ready to cut the hole. Make sure if you are standing on something that it is safe and secure, maybe even held steady by an assistant.
Carefully cut out the hole for the window, following your marker pen line. If you do need to stop during cutting allow the jigsaw to completely stop before removing it from the side of the vehicle.
When you get to the end of the cut you could get a helper to assist on the inside by holding the piece that you have cut away.
File or sand the sharp edge with a file or emery paper. Once you are happy that the edge is no longer sharp it’s the right time to do a trial fit. You are looking for a small clearance of 1 to 2mm all the way around to prevent any ripples forming in the bodywork due to expansion in hot weather. The cardboard template can be helpful to use for checking the size of your hole.
If you are happy with the size, remove the masking tape, if you need to remove any more metal, mark it carefully and either file using a half round file, sand using emery paper or cut it away, depending on how much you need to remove.
Now it’s time to prepare for bonding the window into place.
You need to select an appropriate adhesive sealant to fix the window into place. We recommend that you closely follow the manufacturers instructions on how to use the product that you choose.
We don’t recommend products that will be suitable for your particular application as every installation will potentially be different. Please look at manufacturers such as Sika and Bostik to find a suitable product. Don’t be tempted to use a product that is not recommended for automotive, caravan or motorhome use.
Degreasing the bodywork where you will be bonding the window is essential. Use Methylated spirits or panel wipe but always carry out a small test on an inconspicuous area to ensure that it will not damage your paint. It is also worth degreasing the inside edge of the flange of the window as you will have been handling it during the process up to now.
Apply a bead of your chosen adhesive sealant to the rear of the frame. Try to keep the bead to a consistent size and in the same position on the flange. Immediately put the porthole into the opening ensuring that the centre bar is horizontal and the drainage hole is at the six o clock position.
Push the window in firmly until sealant comes out at the sides of the flange. Clean away any excess sealant quickly with cleaning wipes suitable for the job. Check inside to see if there is any excess adhesive to remove. Secure the window in place with some glazing tape or strong masking tape and allow the sealant adhesive to cure properly.
Once cured remove the tape and stand back and admire your handy work and your new Repmac Porthole. Don’t forget to send us a photo of your install, we will put you in our gallery and give you a share on social media if you wish.
We recommend keeping the glass and the rubber seals clean to avoid scratching. Also we recommend squeezing the catch when both opening and closing the window.
Enjoy your Repmac Porthole!
LARGE & SMALL - RIGHT & LEFT HAND OPENING FITTING GUIDE
The correct positioning of your Repmac Large or Small window is very important. This product is designed to be fitted on any flat panel on the side of your vehicle. These windows must not be used on the roof of a vehicle. Before cutting any panel please ensure that you have carefully inspected inside the vehicle to make sure that there are no structural components, cables or other obstructions.
If you need to check if the desired fitting location is flat then we recommend using a spirit level or straight edge as close to the size of the window as possible. Place this on the side of the vehicle in the desired location, if it does not sit flat then the panel is not flat and the location may not be suitable to fit the window. The most likely curvature of a vehicle is vertically from top to bottom, so please check this carefully.
Once you have chosen the fitting position then please use the cardboard template provided. We recommend checking that you are happy with the template by placing it on the rear of your window and satisfying yourself of the tolerances that you have to play with.
Using a wide low tack masking tape to protect the vehicles paintwork is recommended. Tape off a rectangle with the template sitting approximately in the centre of the tape.
Position the cardboard template and secure with a few pieces of masking tape. Draw around the template with a suitable fine nibbed marker pen. Remove the template and check your line carefully.
As all good tradesmen say ‘measure twice cut once’. Check and double check before you attack your beloved vehicle with any kind of cutting implement.
Once you are happy with your marking out, you need to select your weapon of choice. We recommend a Jigsaw with a brand new blade suitable for the material that you are cutting. Most of the time this will be thin sheetmetal if you are cutting out a panel van or similar. You need to use a fine tipped metal cutting blade suitable for the application. If in doubt ask the supplier or read carefully on the packet.
Ensure that there is sufficient masking tape to the outside of the cut line. The jigsaw bed will vibrate and rub on the paint when you cut and the masking tape will prevent scratches to the vehicle paintwork.
You will need a HSS drill bit (High Speed Steel) to drill a hole big enough to pass the jigsaw blade through. This will vary depending on which blade you choose for the jigsaw. It it a good idea to drill a smaller hole first and then use the bigger drill bit to open up the hole to the desired size.
With the appropriate sized drill bit, drill a hole on the inside of your marked line with your drilled hole touching or very close to the line. Don’t push too hard and let the drill bit do the work to avoid denting the panel.
You’re now ready to cut the hole. Make sure if you are standing on something that is is safe and secure, maybe even held steady by an assistant.
Carefully cut out the hole for the window, following your marker pen line. If you do need to stop during cutting allow the jigsaw to completely stop before removing it from the vehicle.
When you get to the end of the cut you could get a helper to assist on the inside by holding the piece that you have cut away. This is particularly important for the Repmac Large Windows, the metal that you cut away will be surprisingly heavy.
File or sand the sharp edge with a file or some emery paper. Once you are happy that the edge is no longer sharp it’s the right time to do a trial fit. You are looking for a small clearance all the way around to prevent any ripples forming in the bodywork due to expansion in the hot weather.
If you are happy with the size, remove the masking tape, if you need to remove any more metal, mark it carefully and either file, sand or cut it away, depending on how much you need to remove.
Now it’s time to prepare for bonding the window into place.
You need to select an appropriate adhesive sealant to fix the window into place. We recommend that you closely follow the manufacturers instructions on how to use the product that you choose.
We don’t recommend products that will be suitable for your particular application as every installation will potentially be different. Please look at manufacturers such as Sika and Bostik to find a suitable product. Don’t be tempted to use a product that is not recommended for automotive, caravan or motorhome use.
Degreasing the bodywork where you will be bonding the window is essential. Use Methylated spirits or panel wipe but always carry out a small test on an inconspicuous area to ensure that it will not damage your paint. It is also worth degreasing the inside edge of the flange of the window as you will have been handling it during the process up to now.
Apply a bead of your chosen adhesive sealant to the rear of the frame. Try to keep the bead to a consistent size and in the same position on the flange. Immediately put the window into the opening ensuring that the window is the correct way up!
Push the window in firmly until sealant comes out at the sides of the flange. Clean away any excess sealant quickly with cleaning wipes suitable for the job. Check inside to see if there is any excess adhesive to remove. Secure the window in place with some glazing tape or strong masking tape and allow the sealant adhesive to cure properly.
Once cured remove the tape and stand back and admire your handy work and your new Repmac Window.
We recommend keeping the glass and rubber seals clean to avoid scratching the glass when opening and closing the window. Also we recommend squeezing the catch when opening and closing the window.
SKYLIGHT
The correct positioning of your Repmac Skylight is very important. This product is designed to be fitted on the roof of your vehicle. Before cutting any holes, please ensure that you have carefully inspected inside the vehicle to make sure that there are no structural components, cables or other obstructions.
You are likely to need a blanket and a board to spread your weight when you are working on your vehicle roof. Take extra care to make sure that you are safe and you won’t scratch your vehicle in the process. A second pair of hands will definitely be beneficial.
If you need to check if the desired fitting location is flat then we recommend using a spirit level or straight edge as close to the size of the Skylight as possible. Place this on the roof of the vehicle in the desired location, if it does not sit flat then the area is not flat and the location may not be suitable to fit the Skylight. Generally the more you move way from the centre of the roof the more likely you are to experience a curvature.
Once you have chosen the fitting position then please use the cardboard template provided. We recommend checking that you are happy with the template by placing it on the rear of your window and satisfying yourself of the tolerances that you have to play with.
Using a wide low tack masking tape to protect the vehicles paintwork is recommended. Tape off a rectangle with the template sitting approximately in the centre of the tape.
Position the cardboard template and secure with a few pieces of masking tape. Draw around the template with a suitable fine nibbed marker pen. Remove the template and check your line carefully. Many vehicle roofs will be corrugated and this makes the marking process particularly tricky. Take care to do this accurately, viewing your line directly from above with the template still in place will highlight if your line is in the correct position.
As all good tradesmen say ‘measure twice cut once’. Check and double check before you attack your beloved vehicle with any kind of cutting implement.
Depending on the stage of your build, you may decide to tape a dust sheet or piece of polythene to the inside of your vehicle. This will catch any swarf rather than it going inside.
Once you are happy with your marking out, you need to select your weapon of choice. We recommend a Jigsaw with a brand new blade suitable for the material that you are cutting. Most of the time this will be thin sheetmetal if you are cutting out a panel van or similar. You need to use a fine tipped metal cutting blade suitable for the application, if you van has particularly tall corrugation you may be better to have a longer blade. If in doubt ask the supplier or read carefully on the packet.
Ensure that there is sufficient masking tape to the outside of the cut line. The jigsaw bed will vibrate and rub on the paint when you cut and the masking tape will prevent scratches to the vehicle paintwork.
You will need a HSS drill bit (High Speed Steel) to drill a hole big enough to pass the jigsaw blade through. This will vary depending on which blade you choose for the jigsaw. It is a good idea to drill a smaller hole first and then use the bigger drill bit to open up the hole to the desired size.
With the appropriate sized drill bit, drill a hole on the inside of your marked line with your drilled hole touching or very close to the line. Don’t push too hard and let the drill bit do the work to avoid denting the panel.
You’re now ready to cut the hole. Make sure if you are standing on something that is is safe and secure, maybe even held steady by an assistant.
Carefully cut out the hole for the Skylight, following your marker pen line. If you do need to stop during cutting allow the jigsaw to completely stop before removing it from the vehicle.
When you get to the end of the cut you could get a helper to assist on the inside by holding the piece that you have cut away.
File or sand the sharp edge with a file or some emery paper. Once you are happy that the edge is no longer sharp it’s the right time to do a trial fit. You are looking for a small clearance all the way around to prevent any ripples forming in the bodywork due to expansion in the hot weather.
If you are happy with the size, remove the masking tape, if you need to remove any more metal, mark it carefully and either file, sand or cut it away, depending on how much you need to remove.
Now it’s time to prepare for bonding the Skylight into place.
You need to select an appropriate adhesive sealant to fix the window into place. We recommend that you closely follow the manufacturers instructions on how to use the product that you choose.
We don’t recommend products that will be suitable for your particular application as every installation will potentially be different. Please look at manufacturers such as Sika and Bostik to find a suitable product. Don’t be tempted to use a product that is not recommended for automotive, caravan or motorhome use.
Degreasing the bodywork where you will be bonding the window is essential. Use Methylated spirits or panel wipe but always carry out a small test on an inconspicuous area to ensure that it will not damage your paint. It is also worth degreasing the inside edge of the flange of the skylight as you will have been handling it during the process up to now.
Depending on the size of the corrugations in your roof, sealant alone may not be enough to fill the gap between the skylight frame and the roof. In this situation we recommend finding a product that can easily be cut and bonded into place. It also needs to be waterproof and doesn’t swell should it ever get wet. PVC Foamboard is suitable, readily available and easy to cut.
If using PVC Foamboard you will need to buy the correct thickness to make up the gap allowing at least 1mm for adhesive sealant underneath. Essentially you are trying to use the product to make the low parts of the corrugated roof the same height as the high parts to create a flat surface to bond the frame to. Make sure that the PVC Foamboard is cut 5mm inside the outside edge of the flange to allow for a bead of adhesive sealant.
We recommend dry fitting the Skylight into place and masking around the outside of the frame leaving approximately 5 to 10mm for a bead of adhesive sealant. This will make it much easier to make a neat job of the sealant, particularly when you are gap filling.
Apply a generous bead of your chosen adhesive sealant to the rear of the frame and to the top of the roof and any filler pieces. Try to keep the bead continuous, to a consistent size and in the same position on the flange of the frame and the roof. Immediately put the Skylight into the opening.
Push the Skylight in firmly until sealant comes out at the sides of the flange. Wearing tight fitting latex gloves you can use a finger to smooth the sealant adhesive down onto the masking tape, if you prefer you can use a silicone smoothing tool. Ensure that there are no gaps in the sealant adhesive. You will more than likely need to add more sealant adhesive during this process.
Once you are happy remove the masking tape carefully and use suitable cleaning wipes to tidy up any sealant adhesive where necessary.
Check inside to see if there is any excess adhesive to remove or smooth out. Allow the sealant adhesive to cure properly. We recommend not opening the Skylight or driving the vehicle until the sealant adhesive is fully cured.
Admire your handy work and your new Repmac Skylight.
We recommend keeping the glass and rubber seals clean to avoid scratching the glass when opening and closing the window.
As ever, we are on hand to offer support and advice for any issues or questions that pop up on the way. Drop us a line here…
