You may want to have a look at how they fit windows to van sides, as this seems the easiest way to fix the window and keep the stability. A single sheet of plastic may flex a bit much for the van and may be liable to crack in differing weathers unless you have a flexible sealant. Personally I would find 3/2 windows from a breakers and then rebuild the frame to fit those windows. You then have the stability and the ability to put rubber seals around. To get the water out of the windows, take out the rubber dots and use a vacuum cleaner to suck it out. Then just use a piece of clear tape to seal (don't know if you can get replacements) or PVC glue the crack. Good luck
Quote: Originally posted by Marcrod on 25/6/2013
No, I salvaged the bottom shelf, but had to make the top shelf with a 30deg cut. I used a cheap Rhobi jig saw, that has the ability to tilt the blade and then just stuck to the line really well. If you still have the old shelf, I would sand it down until you reach good wood as then add a layer of chip board or 3mm ply to reinforce. I used a piece of hardwood for the shelf (to stop it warping when it dries properly) and this cost me more than the frame (£18.50 for a 2m x 150mm) piece.
I have finished now and it actually looks ok. I will have to make some tape from the left over wallboard to cover a couple of cutting mistakes, but overall I'm impressed at how easy (technically) the job is. It's just time consuming and requires patience.
For the weatherproofing of the main spars I used some aluminum tape on the outside, stuck about 1inch onto the ABS and enough so I could wrap a flap around the wood. I then used some liquid rubber (£10 ish off eBay) to give my old seals the bet chance of being water tight and painted it onto the main spars (that are covered in ally tape) and carefully over the edge of the seals that touch the ABS.
Take care when it comes to re-fitting curtains, as I guessed and now have one curtain that needs to be slightly adjusted.
If you do need to take the front overhead lockers out, then I found there were screws coming down from the underneath the roof. I took the drastic option of basically, whilst removing all the ones I could, ripping the wood from the ceiling. I destroyed the holding wood (try not to damage the furniture it's self, but then added a couple of screws where the down ones were to screw it back up. To get rid of the hanging screws I used a pare of tin snips to snap te screws flush to the wood above.
I hear the weather is good this week. Good luck
Hi could you tell me where the abs panel lays on the top of the window frame mine was stapled and this is where the cracks started from.did you fasten yours to the frame if so how.this is the only thing stopping me carrying on.
Thanks
------------- landrover discovery td5 followed by elddis elusion 510/6
Hi marcrod
Glad your rebuilds gone well,I rebuilt the front end of our whisp 350/2 new window frame etc cracks was reinforced with 3mm abs on the inside and abs paste on outside.After a couple of outings very small crack's appeared again on the outside due to movement I suppose. I decided to get some 0.5mm aluminium sheet & cut about a 3" strip just a bit wider than the front window.
This was moulded to shape & stuck on with sikafex 512.
It as covered all area's that was prone to cracking & left a nice looking finish that looks like it should be there. We have now been leak free for a good 12 months with lots of outings.
All the best
Kev
The ABS on mine wasn't stapled and really shouldn't be. That's just asking for weak points. If you have to secure it, then I would suggest drilling small holes and using small all weather screws. I'd also reinforce the outside of the holes with some ally tape, to stop any movement cracks growing.
The only securing holes on the ABS should be under the rail above the window, so staples are useless, as they are only there to hold in place temporarily.
I now have another van, but we had 6 months of water tite camping in the forests with the van after the repair and as far as I know, it's still going strong 😊
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Topic: Elddis Wisp 400/4 Front End Rebuild
