Why a Template Matters for Campervan Window Installs
Installing a CRL AW1033 awning-style window in your camper van can be a daunting process—especially if you’re trying to avoid leaks, poor seals, or unnecessary stress. In this detailed guide, we’ll walk you through how to create a highly accurate cardboard template to simplify your installation. By the end, you’ll have a reliable method to replicate the perfect cutout for both sides of your van.
This tutorial is part of our larger van conversion series, and while the full window installation is in a separate video, this guide focuses on building a cardboard template that ensures precise and consistent results.
Why We Use CRL AW1033 Awning-Style Windows
Before diving into the template process, let’s quickly go over why the AW1033 windows are our go-to choice:
- Awning-style design lets you keep windows open in rain or snow without letting moisture inside.
- Integrated screen keeps bugs out while still allowing ventilation.
- Dark factory tint for enhanced privacy and sun protection.
- Foam gasket system (not adhesive) provides solid waterproofing when installed correctly.
This style is ideal for van lifers who camp in a variety of weather conditions.
The Common Issue: Poor Fitment Leads to Leaks
Many DIYers run into the same problem: the included compression ring flexes and doesn’t provide an accurate template. This leads to oversized cutouts, poor gasket compression, and in some cases—leaks at the corners.
That’s why we build our own custom cardboard template, directly measured from the window’s actual mounting rim, not the flexible inner ring.
Tools & Materials You’ll Need
To create your window template, gather the following:
- CRL AW1033 window
- CRL shipping box (used as cardboard material)
- Fine-tipped permanent marker
- Razor blade with a fresh blade
- Drywall square or straight edge
- Masking tape
- Calipers or measuring tape
Step-by-Step: Building the Cardboard Template
1. Prepare the Cardboard
Disassemble your CRL shipping box and flatten it. Choose a portion large enough to trace the entire window outline.
2. Measure the Mounting Rim
Avoid tracing the flexible compression ring—instead, measure the true outer edges of the window’s mounting rim, where it will pass through the van’s sheet metal.
Recommended Cutout Size (Estimated):
- Width: 32.5″
- Height: 10.5″
Always verify your own window dimensions!
3. Square the Edges
Use a drywall square to mark and cut straight, right-angle edges on the cardboard. This ensures your template sits level when you trace it onto your van wall.
4. Trace the Window Cutout
Lay the window flat on the cardboard. Tape it down on the sides to prevent movement. Use a fine-tip marker to trace the window’s outer mounting rim precisely.
5. Cut the Template
Using a fresh razor blade, carefully cut along the outer traced line. This will be your master template.
⚠️ Pro Tip: Avoid cutting too much—you can always trim more later, but you can’t add material back if your hole is too large.
6. Trim the Corner Radii Precisely
The most common source of leaks with AW1033 installs? The corners.
To fix this, shave the corners of your template directly while it’s taped to the window, using the frame as a guide. This helps you match the tighter radius needed for a good gasket seal.
Why Tight Tolerances Matter
If your window cutout is too large:
- The foam gasket won’t compress properly.
- Water can seep into the van.
- The install will look sloppy.
By ensuring tight, accurate cutouts with your template, you’ll get:
- A cleaner install
- Better waterproofing
- Less stress during mounting
Bonus Tip: Upgrading the Screw System
The included screws with the AW1033 aren’t ideal. They tend to bottom out, preventing proper clamping pressure. For a better install:
- Replace with M4 socket head cap screws
- Drill pilot holes and tap with M4 threads
- This will provide better gasket compression and reduce leak risk
Interior Finish with Flatline VanCo Trim Ring
To finish off your install inside the van, we recommend the Flatline VanCo trim ring, which:
- Fits perfectly with the AW1033 window
- Matches the Adventure Wagon interior panels
- Provides a clean, finished look while accommodating insulation thickness
Final Steps: Trace and Cut Your Van Wall
With your cardboard template ready, it’s time to:
- Tape the template to your van wall in your desired location.
- Double-check measurements and alignment.
- Use a drill or jigsaw to cut along the template lines carefully.
- Insert the window, apply compression ring, and fasten with upgraded screws.
Conclusion
A proper install starts with a precise template. Don’t trust flexible plastic frames or take shortcuts on measuring. A little extra effort during the template stage can save you major headaches—and leaks—later.
This cardboard method ensures you have a repeatable, accurate cutout process for both sides of your van. Whether you’re outfitting a single rig or converting multiple vans, this is the foundation for a professional window install.
