How to align AVC RIG van wall panels with window cutout
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May 2, 2025
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View Video Transcript
0:00
[Music]
0:47
hey everyone welcome back to the shop hope everyone had a very happy holidays
0:53
and uh we are working on one of the more challenging parts of the van so this is
0:58
uh the wall panels for the uh install in the van these are the ones that we are
1:05
using from ABC rig so these panels are pre-cut so they're cnced uh they're
1:10
labeled and they are specific for a bunch of parts of the van so if you guys are looking for a wall penel kit uh this
1:18
is not a sponsored video but I wanted to show you what we're talking about so if you go to ABC rig uh.com and you go to
1:26
the transit 148 wall kit so that's where a Ford Transit it so we're going to take a look at this
1:33
this is what we uh purchased for our customer and one thing you can do you can make your own panels but again this
1:40
there's this uh kind of cost benefit between the time you want to put into your van versus your skills now I have
1:48
the skills to make these panels but TimeWise uh I need to get that time back
1:53
so that they can have their van done by a certain time so to buyback that time
1:59
we uh together will get these panels it'll speed the process up um so we're
2:05
not having to cut everything measure and stuff like that so um pretty normal
2:11
there are panels from ABC rig Titan Vans DIY Mak some panels uh but ABC rig the
2:18
reason I chose these um was because uh I think it's a very good price point two I actually um met the uh
2:28
one of the owners at the adventure van Expo and we went to did a whole video on
2:34
these uh on a tour of his van so for me as a builder I can go back to this video
2:39
I can check out how everything was laid out and I'm just more comfortable going forward with uh a product like this and
2:47
the fact that I got to see it in real life so that's a benefit to you guys as
2:52
well you might want to do the same thing if you guys are going out to shows van shows throughout the year that's a
2:59
really good so so if you're not looking for spe specifically a builder and you have the intention for going out and
3:05
doing a DIY really pay attention when you're in the van you know not just talking meeting um you know Builders and
3:13
their products but actually take some pictures really look at the details and think of how you would actually install
3:19
these panels yourself put yourself in that mindset and when you're there in
3:25
the van and you have some questions you'll be able to ask the person that's actually made making the product or
3:30
selling the product um and it makes going to a show uh just that that
3:36
better so I'm going to zoom in here so as you can see these wall panels these are bare wall panels uh you can get this
3:44
in an underlayment material so you know just the basic uh you know quarter inch
3:51
luon type style which is what we bought because I'm going to paint them and
3:56
upholster them so as far as the wood uh being used as something that we would
4:01
stain or have as a feature that's not what we're doing they also make it in a Baltic Birch panel but that's an
4:08
additional cost uh which is for us not necessary but for you might be something you want to look into if you're thinking
4:14
of actually maybe staining these panels doing a clear coat or something like that now again the topic of this video
4:22
is how to align the panels but let's get familiar first with wall panels in
4:27
general and why aligning a window to it uh with something that you're going to
4:34
look forward to doing so this is the panel kit that we put in the van and uh you can see we have all raw
4:42
panels and that's what we start with so these panels have a specific location
4:47
because they have a specific location that means when you cut out a window the window has to match up to the back of
4:54
the panel and then you need to translate that uh cut out to the back of the panel
5:02
and then cut the panel out because the panel can't move and the window can't move so you have to figure out how
5:08
you're going to marry those two together and it needs to be perfect uh you know
5:13
within an eighth of an inch um or better if you can and sometimes that might be a
5:18
scary thing to do if you've never done this before uh but guess what I have not done this with this panel kit so you're
5:25
along the ride with me and uh that's why I hopped in the today got on this live
5:31
stream so that I can make a video showing you how I approached it um and
5:36
then how I'm actually going to make this uh into something that I'm you know proud of building and it's nice and
5:44
accurate so there's the panels uh we'll talk about this later during the build uh we'll be covering all this throughout
5:50
the build but these metal pieces right here this is uh these are just the angle
5:56
supports it helps you with the transition between the wall going vertical versus the horizontal uh when
6:03
you have the inner uh the intersection between the wall and the roof in the
6:11
ceiling so we have those we're not putting those in yet because we need to figure out
6:17
first oh by the way it comes in a a really nice uh shipped
6:23
box so all right enough of that that's what we're working with just so you can get
6:28
your kind of mind around it now look here this is the panels but they are
6:33
upholstered and they have these window pill cutouts so the window pill is a product
6:41
that they also sell let me see if I can pull it up real
6:48
quick so what these window pills are designed to do is they take up the Gap
6:54
this difference between the wall panel and the window
7:01
if you guys were watching the video on the adventure wagon install those were thermoformed panels and they give you
7:08
the bump out space um but because of the orientation that this customer wants to sleep in the
7:14
van we're not doing bump outs because we want the long uh kind of north to south sleeping versus east to west now the
7:22
benefit of a north to south sleeping Arrangement is you can add much more insulation in the
7:27
wall and you get uh just a much better Comfort level in my opinion because you're adding more
7:34
insulation in the van it's just easier to heat and cool um as you can imagine this chamber is filled up with insulation versus if
7:40
you had the bump out there's a very thin layer of insulation and uh you know
7:46
might not be as um efficient insulative wise so this space right here is what
7:53
the window pill is designed to make up the difference so it'll make the transition between your uh bunk window
8:00
and the wall possible so that's what we're doing today so we have two of
8:07
these um we've already set it up in the van we've measured we've we've found out
8:12
our spacing and I'm going to go through the whole process uh to show you how
8:17
I got to where um I am right
8:23
now let's see if there's anything else I wanted to show you guys oh by the way when you get these you see how it says
8:30
uh crl V w133 and a1033 so that's very important the VW is
8:39
the the vent window that you see in this photo so it just slides open slides shut um as you guys know I'm a fan of
8:47
the awning style windows so we're going to be using the aw 1033 window so this
8:54
is the awning style window so when this window opens up
9:00
we have an awning that comes out so that when it's raining the water Can Shed off
9:07
of here but you still get the ventilation um it also has a bug screen
9:13
but I've I've taken that
9:20
out all right so what we're going to do is let's see
9:27
here so let's let's go to all right let's go over here to the
9:37
table so this is our window vent that I just showed you and what the
9:46
what this window pill does is this will go over the
9:52
window you guys can see that so it goes over like that and and
10:00
it um there we
10:06
go so it's going to go over the window frame create that difference uh but
10:12
here's the challenge how and what this video is on how do you
10:17
align this to the window and then align it to the panel so that you can cut it
10:23
out uh so I'm going to try to draw that for you guys
10:29
and show you how I did
10:41
it so if we look on the side of the van we're going to draw
10:47
uh so this is the side of the van okay there's the
10:57
front and we need to put a window right here I know this is not the specific
11:05
spot so there's the window and then an orange here let's say that this is our
11:11
wall
11:18
panel so the wall panel is going to be fixed we can't do anything about it the
11:23
window is probably going to be in a fixed location so if you watched my last video there was these uh Center ribs
11:30
that I wanted to make sure that the window was centered in so that is how we
11:36
found our window um let me just go to it you guys might
11:43
have may not have seen the other video so check this video
11:52
out um this one's called install your crl a1033 windows the right way so this
11:58
is how I show you how I put the window in the van and
12:04
then why it's important to make sure there's a nice clear offset at the top of at least an eighth of an inch so that
12:10
when we upholster this foam pill or window pill that we have enough room to pop it
12:17
around the window frame so what I did here is I put the window
12:22
in I put my window frame in I put the foam window pill on here and then I
12:29
taped everything into place the next step is I took the whole entire wall panel and I laid the wall panel on top
12:37
of the window uh let me back
12:47
up so I removed the window so that I could
12:52
actually draw on the inside let here let's
12:57
see I wish I would have taken a time lapse of it uh I had a lot of back and
13:03
forth so that's why I'm making this video because that way you guys won't have to go through the hassle that I
13:10
went through not hassle it's just mainly how to uh just part of building a van so
13:17
we're looking at a side profile of the van uh let's just say this is the tire okay this is the wheel
13:23
well so we're going from the back of the van this is the outside side of the van
13:30
and then this is the inside of the van so in the van you're going to have a piece of sheet metal then you're going
13:38
to have uh some support members that come out like
13:46
this your window is going to be located here and I know it doesn't pop out I
13:53
just want to make something so you guys can see what's going on so this is your
13:58
window uh this next part right here is your window
14:04
frame not the window pill but the window frame of the crl crl awning
14:10
window and then last we're going to have this uh
14:16
foam window pill that goes like
14:27
this now this is a cutaway side view if it
14:33
this looks really weird to you
14:41
guys so that's our foam the pink is our foam window
14:48
pill there we go there's my so there's our foam foam the Orange is the metal
14:55
for the Cal to hold it in and then the blue is the actual glass GL awning
15:01
window next what we have is we've got the van panel itself so
15:08
let's make that green so the van panel comes here like
15:13
this and what I did is I took the window out so I I took this window
15:22
out so let's represent that
15:27
by erasing
15:34
this so I took the window out and then I took a marker or a permanent
15:43
marker and I went through and I just I traced that inner part of the wood so I
15:51
traced the inner part of the wood so if you go back here what I did is I went into the window and I took a marker and
15:57
I went all the way through through here and I trace the inside of the window just like that when I was done
16:05
tracing the window I then uh I took this panel off
16:12
so I unbolted this panel so by bolting the panel in place
16:18
first and then tracing it second I'm able to lock in exactly where the window
16:23
is and then so if you can imagine this panel
16:37
so this panel is in the van there you go and imagine that this
16:44
is up against the wall and so I took the panel and then
16:49
I temporarily bolted it to the wall and then I went into here and I
16:57
traced and I went into here and I traced out the cutout that way this was taped
17:03
in place this was not moving and when I removed this panel what I was left
17:16
with what I was left with is this tracing so this is what has been traced
17:22
out so all I have to do is drill jigsaw this out and now this will be and will
17:29
be a perfect copy of where my window cutout
17:34
is and then all I have to do once I upholstered this panel and upholstered
17:41
this you can see that these window pills what I've done is I've taped them together they're eventually going to be
17:46
glued together one side has this wood side that's the hard rigid side and
17:54
then you have the foam so this hard rigid side is what we're going to drill
18:03
into so for example if we go back to this you see how they have these
18:10
screws so these screws are going through the wall panel and then they're going into that wood that outer piece of wood
18:18
on the foam to bolt it together it's not necessary to do that
18:24
on the opposite side so the reason that this is only wood on one side and then foam cuz this
18:32
foam is just going to uh I'm going to put some ad just a little bit light
18:38
piece of adhesive and I'm going to adhes that to the seral window frame after I upholster
18:47
this um actually take that back I'm upholstering this so uh it's my point is
18:55
it won't be necessary because this panel is going to push push against this into
19:01
the window frame and so that pressure is going to be there forever it's not going
19:07
to be able to come out because it's it's not possible uh one thing you do want to
19:12
make sure is you put some Marks here so that your orientation of this is perfect
19:19
I'm not saying that these window pills are not perfect cuz they're probably cnced machine but uh I did notice that
19:25
one side was a little bit thicker than the other just by like an eighth of an inch so you don't want to do this
19:32
measure your whole cut out and then install it like this uh you don't want don't want to do
19:40
that so once you have this on here
19:45
uh everything's pretty much mapped out for you the last step is to actually cut
19:52
out the hole um so we're going to cut out this hole and then I'll show you what it
20:01
looks like um but the reason I say this is probably the most challenging part of a van is
20:09
you have to meet up the window with the van panel once I do this the other side just
20:15
kind of copy copy paste and it'll be much easier um The Challenge like I said is
20:21
just because this is a CNC cut and it's made to go in a specific location so
20:26
there's this is actually buting up to other panels so if I mess this up I
20:32
can't shift this backwards or forwards or up or down because there's other panels resting against this
20:45
um all right let's see if there's anything else I wanted to show
20:53
you um well before we cut our hole and keep going with this video that's pretty much the core part of the video next I'm
21:00
just going to be cutting this out but when we do get to the upholstery of
21:06
this uh this is going to be an interesting piece to upholster because it's not going to be
21:11
our typical way that we do
21:16
it so let me get some fabric so typically when I upholster
21:24
something or you guys have seen on the channel I'll lay the piece of upholstery out I'll lay my piece on it I'll measure
21:33
everything out and then I'll fold this around to get uh to get it to where I
21:38
want it to so this one you have to think opposite so we're not aoling this face
21:45
and this face we are the reveal is going to be the inside of this so you got to think
21:52
differently how do I impul how do I impulser the inside so you have to pretty much much
21:58
take back anything you've learned from me on the upholstery cuz we are going to we have to do this completely opposite
22:04
so we're going we'll be going on the inside like
22:10
this think of like a u
22:22
shape so we're going to be taking the material
22:36
okay and we're going to be doing something like this so we're going to have this flat and then the uh the front
22:44
face is actually what's going to be rounded over like that and then that way it'll be rounded
22:50
over here and the backside and we don't really care what
22:56
happens down here we'll make it you know neat as we always do but we're going to wrap it around like that and then this
23:03
is the face that's going to mount up to the back of the panel which will also be upholstered and so once those two faces
23:09
meet this is what gets screwed into now obviously I flipped this the wrong way
23:15
this is the would be the wood side uh and then what we're going to do for our
23:20
seam is we're going to we'll cut this off uh we'll fold this back uh maybe
23:27
like an inch like that um I'll probably iron it and then
23:33
that uh lip right there is going to go on the top we want it on the top because when
23:40
you're laying in bed you'll see the sides in the bottom but this top right here will be
23:46
concealed and even when we get to the top and we fold it over like that this seam you won't see because the
23:54
wall panel is going to cover the top of it so this should upholster really
24:00
nice uh I'm curious I have upholstered over foam
24:05
before uh but this rigid foam we we'll see uh
24:12
how it reacts we need to glue this first but if here I'll show you an
24:17
example so you see how this is a perfect flat
24:22
surface and then this the CNC machine see how it's not
24:30
perfect but the inside is so see how the inside so that inside face is clean and
24:38
this bottom is clean that's all we care about don't worry about this you'll never see this it'll be hidden behind
24:43
the panel just make sure that this surface and this top surface and the
24:49
sides are uh nice and flush because the only
24:55
thickness you'll have to make up anything is whatever type of fabric you're
25:01
using all right so we are going to we'll upholster this and this uh
25:09
probably in a separate video that's my coffee
25:18
maker and uh right now what I want to do is drill and cut this out just to show
25:24
you you know what it looks like then hopefully you guys have some
25:29
questions whether you're watching it live right now or later this
25:34
afternoon um but I'll probably end with just cutting this out and then showing
25:41
you the example before it actually gets upholstered all right so what I'm going
25:47
to do is I'm going to get my trusty brake caliber counter
25:56
weights I love using them just an easy way to have a second pair of
26:07
hands plus I got to paint the panel I got to upholster the panel and then drill
26:12
everything uh I might be able to do a live stream this afternoon when I have all that done that's my goal today is to
26:18
just get this knocked out um we've got good news so
26:25
Thursday uh we will be getting our nomatic 48volt rooftop AC unit
26:34
delivered and it's pretty exciting because uh I believe we are going to be
26:39
one of the first deliveries of this unit um I've been really trying to get on the list as far as being the first one to
26:46
get it and I got a call today from the shipping
26:52
company asking me if I'm going to be at the shop Thursday and I said absolutely
27:00
so that's going to be exciting because we are pairing that up with the 48 volt ecoflow uh 5 KW hour system uh for this
27:10
van and so if I get these two panels done today that'll be a big check off
27:15
before we actually start to do cutting holes out of the roof um as well as our
27:21
other window that we got to cut out on the other side yeah so let's go ahead and I'll
27:27
show you how to cut this out which is it's pretty simple um all we're going to do
27:33
is uh we'll drill a pilot hole so that we can fit our jigsa blade in there and
27:40
then we're going to follow right on the line so we don't want to go outside of the line we want to go right on the line
27:48
and that's going to allow us to make sure that we have the same difference when we overlap our upholstery on this
27:54
panel and when we overlap it on that because because we want to keep that the same so there's not a
28:00
ridge um that we have to deal with later uh also we don't want to make this
28:07
hole too big because they're going to have a weird Ridge where you'll see that window
28:12
box and this will be cut out more so when you go to trace this visualize when
28:18
you're tracing as if you're taking the saw blade and cutting it out you want to make just make sure that this is this
28:25
line is even to that um yeah so I'm going to mute my mic
28:33
really quick because it's probably going to be crazy loud and then
28:39
uh I'll be
28:56
back
35:14
okay we just cut the hole
35:22
out now if you're worried about making a straight line you could use you know a track sve for the straight
35:28
Parts um I've just used jigsaw forever
35:33
that um I've got pretty good with making extremely straight lines but this is
35:41
the let's get this in the right orientation since we have a
35:53
second all right so this is how it goes in the van
36:02
H can I creatively do
36:12
this okay maybe
36:25
not
36:42
that too high for the
36:49
camera all right let's check this
36:55
out
37:09
all right so here's our panel this is what goes on the driver's
37:14
side so this is the back of the van where the van doors are this side is
37:21
where that weird Notch is on the Ford Transit so now we have our
37:27
window cutout and if you can imagine what we'll have next is we will have
37:34
our uh we'll have our window frame and this
37:41
will screw together screw on this one just like
37:55
that and this is a good time to check to see if you made any
38:01
mistakes and get this all lined up but if you
38:06
guys can see this is how this is going to be put
38:11
in the van and then behind here we'll have our
38:18
window so the behind the scenes will look like
38:23
this so this is what the back of the panel look
38:29
like now my opinion is you don't want
38:34
to uh I wouldn't pre-drill this to the
38:41
panel or glue this to the panel I would upholster the panel separately I would
38:46
upholster this window pill separately because this window pill is going to go into the window around it upholstered
38:53
and then you want to lay this panel down um you want to be able to probably
39:00
adjust this just a little bit to make sure it's where you want it because not
39:05
only in a van are you working with this but this panel is going to actually
39:13
curved so in a Ford Transit this VY is not going to be like
39:18
this this V is going to be more this panel is going to be more curved this way and so that curve is going
39:28
to uh this window pill will be probably at a slight angle
39:35
at first and then when you form the panel when you Bolt the rest of the panel into the Van Wall it's going to
39:42
conform and then it's going to push against the uh the foam piece so that's
39:48
just uh that is just my
39:54
recommendation all right so so that's um that's what we're doing here
40:00
we're going to uh I'm going to sand this I'm going to go ahead and sand
40:07
paint uh upholster both pieces then I'm going to go and uh
40:15
actually in the van so let's turn this over
40:25
here so I'll go back over here and I'll
40:31
install the window I'll do a final install so I'll go ahead and put the window in uh I'll drill and tap well
40:39
I've already drilled and tapped the holes for the window so it's just going to bolt right into place I'll lock tight
40:44
all those screws and that window will be there in its final position will'll
40:49
upholster the window pill we'll pop that in and then what we'll do is
40:54
we'll get ready to put put this van panel in and then we'll just copy it
41:00
on the other side of the
41:05
van so yeah check out this video um go back through you can kind of see
41:13
actually while we're here I'm going to use the uh see this blue
41:20
color this is where we're wanting to bolt into the window pill frame
41:26
ABC rig has bolt hole locations here and then down here and along the sides we're
41:32
going to uh we'll do a self-tapping sheet metal screw to get this uh bolted
41:39
in but remember this wall I drew it straight but it's actually you know it
41:45
comes it's a more of a curve in the van it's not perfectly straight so that's
41:51
why you'll need this uh this panel is probably going to be like like this and
41:57
so it's going to be harder for I know I ex exaggerated it but if you pre-o it to
42:03
the window it might not line up here that's why I say don't have the window
42:08
pill and the wall preconnected I would do it
42:14
separately all right that is my take today on that
42:21
so thank you guys for joining me in the shop I wanted to uh talk to you guys
42:26
about one more thing and that is the DIY van build cheat sheet so if you guys are
42:31
looking for uh a list of items that are in categories nicely curated parts
42:39
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42:46
done is I have put together an Excel sheet I've organized it with over 250 of
42:51
the products I've personally bought from Amazon over the last 3 years so we have like cargo storage electrical these all
42:58
come with the Amazon links and what's nice is you can go through here you can do you know contrl F and type in let's
43:05
say uh water pump and then you just go through and
43:11
you can pull up uh anything let me type in water pump come
43:20
on there we go so you can look up this one which is the seaflow water pump that
43:26
I use in Vans you can go over here to the link hover over it it's going to show you the pump and it's just a quick
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44:04
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44:21
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44:28
Odyssey Odyssey custom vans I can't even say the name right today Odyssey custom vans this is my custom van conversion
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business and the van behind us as well as this new one that we're building uh for a customer is my business ay custom
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vans we have uh been working on this adventure van uh based on the adventure
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wagon interior system it's an all-wheel drive Ford Transit with EcoBoost uh
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which is the turbocharged V6 if you guys want to do a quick walk through a video walk through we took it to Adventure van
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Expo this year in Chattanooga Tennessee and uh people loved it it was awesome I
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led hearing the feedback from everybody at the show uh it was really exciting to actually get the van out there um so
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everybody could see it subscribers to the channel actually came out we got to say hi hang out for a little bit uh
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really really cool so all the Adventure event Expos throughout the US I really
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would uh tell guys if you can go to one hit up one throughout the year um on the
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East Coast the Chattanooga Tennessee and then the Boston show is uh those are
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probably the two of the closest ones you're going to get to um but if you do get a chance to go out west for example
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um this video where is it that we went and saw ABC rig we went to Colorado so
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we filmed this video in Colorado at the adventure van Expo show there and it was great to see all the you know
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rigs out there it was really cool but yeah check check out this van
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uh this van is currently for sale as of posting of this video we have all the highlights of the van the power system
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the interior that you can check out on the website uh as well as a couple of
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preliminary van photos and I say that because we are getting ready to do a
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final video walk through of the whole entire van uh in the
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future we still have to knock out this back end um but yeah it is close to
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being completely done so before it is finalized you guys can uh check it out
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here with these photos and if you are interested in purchasing it there is still time to
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make a couple modifications uh as of filming this video so if you want to get
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in t touch with me come over check out the van you can contact me at sales Odyssey customs.com also you can call me
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on my office line right there uh the easiest way is to click on this link and
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schedule a phone consultation that way you can get right on my calendar all you got to do is go
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to the link click on a date select a time that works best for you and it'll pop up on my calendar and we can hop on
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a phone call if you're not interested in purchasing the van but you would like to have your own custom conversion van done
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over here on the left are a couple steps to get ready for an online uh over the phone consultation it'll tell you the
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steps of what we do to uh begin to work with you and you do the same process go
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to the calendar select a date that works best for you uh and yeah we can talk about your future van
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conversion all right guys that is going to be it for this live stream today hope you guys enjoyed it hope it was helpful
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um this is just the beginning of this process uh when when I get this painted upholstered in the van um you'll
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actually see the next steps but anytime I'm in the shop and I think something's helpful I just hop on a live stream and
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uh I think it would really help you guys out so if you're not subscribed get subscribed to Van Builder HQ make sure
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you guys give us a thumbs up if you enjoyed this video uh if this is helpful and you have somebody that working on a
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DIY van share this link to them so they can see all the other videos that we have on this channel uh we've got a ton
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we've got Adventure van Expo we got van tours um a lot of shop builds and
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how-tos also don't forget to check out the let me pull up
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here vuer hq.com so we just added a bunch more blogs on here they're going
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over everything from choosing the best camper van inverter best heaters for camper vans which Ford Transit is the
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best camper van conversion and so all of these articles go uh into
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a deep dive for everything that we're talking about uh one that's really good
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the true cost of a van conversion so in this one we go through a bunch of items
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all throughout the van whether it's talking about the electrical system insulation heating water Plumbing
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Systems uh we'll talk about some key takeaways and then we go through and we've got a ton of photos for you guys
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so you guys can check out uh professional build photos you can look at the difference between
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low medium and high roof you know some type of comparison uh this is basically a very easy visual comparison to see
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what the main difference is in each one of these vans so I'll talk a little bit about
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that um I also go over the electrical system and talk about you know what you can expect to spend on certain types of
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uh Power Systems uh insulation in the van what it is why it's important
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different types cost on that uh hea Heating and Cooling there's all kinds of different Heating and Cooling options um
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just stuff to consider rooftop ACS Water Systems interior Vans such as you know
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kitchenet options whether you want to do your own DIY or you can build some pre uh buy some pre-built units might be
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interesting uh camper van lighting you know bathrooms as well as storage options and
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then we'll talk about you know we talk about budgeting for your van upfront cost ongo
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expenses and then do a little wrap up for you um and then also we got the link
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to the cheat sheet in those blog post as well so there's a ton of Articles here
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that I'd love for you guys to click on read get some more information on the
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whole DIY van building world but yeah those are those those are there for you
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guys to uh go to get some help if you have any questions on those definitely
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hop back over to YouTube go into the comments and uh you know ask me a question we can turn it into a future
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live stream um which is usually what I do but until next time uh I will see you
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guys on the next live [Music]
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stream
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