Installing a window in your camper van is one of the most rewarding—and nerve-racking—parts of a DIY van build. In this guide, we’ll walk you through how to install a CRL AW1033 awning-style window the right way, focusing on window placement, measurements, framing, and considerations for your interior layout.
Whether you’re planning around a bed frame, storing bikes, or just trying to get your wall panels flush, this guide will help you avoid costly mistakes and give your van a professional finish.
Tools & Materials You’ll Need
- CRL AW1033 window
- Jigsaw
- Cardboard window template
- Aluminum spacer (1/8”)
- Rigid foam (or wood) for window frame transition
- Underlayment glued to foam or wood frame
- Measuring tape
- Grinder with cutoff wheel
- Marker or pencil
- Drill with small bits (1/16″ or 1/8″)
- DIY Van Build Cheat Sheet (Free tool/resource list)
Step 1: Choose the Best Window Location
Start by planning where the window should go. In this example, the focus is on the rear of the van—perfect for bunk windows.
Key Considerations:
- Garage clearance: Will you store bikes or gear underneath? You’ll need at least 36 inches of space below the window.
- Mattress placement: Make sure your mattress won’t block the window.
- Window height limit: Go as high as possible, but account for structural beams and wall panels.
- Symmetry: Line up the window with your van’s center rib or other visual cues for an even, balanced look.
Use a cardboard template to mock the placement and trace your cut lines. Don’t rush—spend extra time on one side and mirror it to the other when you’re confident.
Step 2: Use a Spacer to Fine-Tune the Height
Once you’ve determined the maximum height for your window, use an aluminum spacer to create about 1/8” of clearance. This accounts for the thickness of fabric or upholstery and ensures a clean fit later.
This is the fixed top position for your window—once the hole is cut, there’s no adjusting. Make sure you’re satisfied with the vertical placement before continuing.
Step 3: Measure Your Bed and Storage Space
Here’s a simple breakdown of how to factor in your garage, frame, and mattress:
Component – Measurement
Total height (floor to window) – 44 inches
Bike storage (garage space) – 36 inches
Bed frame thickness – 2 inches
Mattress thickness – 6 inches
Pro tip: You may need to adjust your mattress thickness or frame material (e.g., switch to 1″ tubing) if you add subfloor layers or insulation.
Step 4: Build Your Transition Frame
To mount your window flush with the interior wall panel, create a foam or wood “window pill” frame:
- The frame steps out from the van’s exterior wall to the interior wall.
- Foam is rigid and light; wood is heavier but just as effective.
- Underlayment glued to the inner edge provides a solid structure for screwing into the wall panel.
- The foam is upholstered for a finished look and attached to the wood backing.
This frame acts as a trim ring and should not be considered structural—it’s there to provide a clean transition and mounting surface.
Step 5: Mark, Drill, and Transfer Your Template
Once the inner template is placed and centered:
- Drill two small alignment holes through the template into the van wall.
- On the outside of the van, place the same template over the holes like a puzzle piece.
- Trace your cutout on the outside panel using the template.
This method ensures your cut is mirrored accurately from the inside to the outside.
Step 6: Cut the Window Opening
Before you cut, mask off the exterior around your traced line. Use a grinder with a cutoff wheel to remove structural beams before using your jigsaw. It’s extremely difficult to cut metal van supports with a jigsaw alone.
Once the structural parts are cleared, use your jigsaw to cut along the marked line.
Step 7: Final Fit Check & Installation
Before you install the window:
- Double-check that your foam frame fits around the CRL AW1033 compression ring.
- Make sure the frame and panel align evenly with the body lines of the van.
- Screw the window into the wood backing behind the foam for a secure fit.
Bonus Tip: Download the DIY Van Build Cheat Sheet
Want to save time and money on tools and materials?
Download the free DIY Van Build Cheat Sheet featuring over 250+ curated Amazon items, including:
- Specialty tools like rivet nut kits and wire strippers
- Ventilation fans, solar components, and water pumps
- All the exact products used in the shop
It’s free and sent straight to your inbox—perfect for beginner or advanced builders.
Final Thoughts
Installing a CRL AW1033 window isn’t just about cutting a hole in your van. It’s about smart planning, precision measuring, and thinking three steps ahead. The window’s position affects your sleeping setup, your storage space, and even your van’s exterior appearance.
By following this guide and using a template + spacer method, you can install your window with confidence and avoid common DIY pitfalls.
Need Help With Your Install?
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