GAMECHANGER: Installing RV Windows on Your Skoolie

Don't get me wrong, I love school bus windows, but they're less than optimal for living with. In this episode I'll show you how you can install an insulated RV window on your bus.
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My name's Chuck, I've been professionally converting buses for the last 8 years and was director of operations for a charter bus company before that but it's time for a change.....
Follow me on instagram for more info
/ chuck.cassady
For paid consults, skoolie advice, solar help, and more, email
[e-mail]
Check out my shop
www.chromeyellowcorp.com
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#skoolie #offgridliving #busconversion

[@sunnydeborahsebastian1361]

I’m binge watching as many of your videos as I can. After watching some other KZbinrs - I like the way you explain things and give sound reasons how you got to a certain product or system. I’m a 70 yo female and in 12 months going to be moving to very rural Virginia. I want a skoolie and want to build it myself, with help where needed. I feel confident that after watching your videos I can avoid the most critical errors. Thanks for your help.

[@ChuckCassadyYT]

Awesome! Thank you!

[@CrysJenkins]

Thank you for these videos. They make me feel much more comfortable and confident in doing my own build soon. What you are doing is so important and much needed in this community, so thank you so much for that.

[@nicholasphillips5406]

Hey Chuck! Would absolutely love if you made a list of Amazon links (or whatever website) in your description of the tools you use. Like the jigsaw and the welding clamp and whatnot. Would be great and convenient for us viewers and could be a nice passive source of income for you with affiliate links. Win win!

[@mkowltra]

Motion Windows has dual pane rv windows and they sell to the public. They have mitered corner option in chrome if you want them to look like true school bus windows.

[@jaytua730]

Man, you really can teach people things, you have the charisma, patience and clear voice. I hope someday I can put together a bus as close as your professional abilities. I am watching all your videos. Good luck and hope to someday meet you and shake your hand.

[@sacredcowbbq1326]

I second that! Confidence and humility- a unbeatable personality combination.

[@charlesb4267]

Having ridden in a school bus as a kid for all those years during the winter with days of -40, I can attest to the USELESS insulating value of a single pane school bus window as well as the aluminum window frames they used and that framing and the windows would be covered in a thick layer of ice on the INSIDE of the bus. Those are the days one wants to be sitting over top of the rear bus heater by one of the wheel wells !, just one of the many reasons I hated school 🤣

[@ChuckCassadyYT]

Absolutely!

[@mmsmits2868]

Once again proving that it all starts with having the right tools. Not every tool is a hammer, and if you're going to start a project like this, make sure you have the tools you'll need. You did an excellent 2-part video on that. Just can't stress how important it is. Thanks for another great instruction video!

[@ChuckCassadyYT]

Thanks for watching!

[@lawrencedobesh776]

I love your methods you’re an excellent teacher! I’m considering a house boat build! I’m considering many of your ideas.which i am sure will work thanks. I would love to see you do a house boat build using a pontoon platform with a small camper on top. Great Ideas great craftsmanship!!

[@mhelp9815]

When putting windows in the walls of my van (OMG! I said it. Sorry) I drilled the holes like you did but connected them on the outside with a marker and used my jig saw on the outside. That way there were no ribs to worry about. I put painter's tape on the outside of the marker line so as not to scratch the sheet metal with the saw.

[@canadianguy2612]

“I love mushrooms, but not in my walls please” Chuck Cassidy Thanks again for sharing your tips and tricks on doing a solid job! Production quality has stepped up too. Looking forward to your next uploads!

[@ChuckCassadyYT]

Thanks for watching!

[@jimross7648]

As always you explain and then show. It makes the information clear for all to see and hear.

[@busconsole]

Great presentation. Clear, informative, and easy to follow. Thanks for sharing this!.

[@michaelirizarry5037]

hands down the best explanation and install demonstration i've seen.

[@richardpoole2729]

Thanks Chuck - always so informative!

[@rtw68]

Enjoying your videos. Doubt I will ever be able to build a skoolie, but if I do, your techniques will definitely be the way I go!

[@moustachemike7128]

Nice job Chuck ...great info as always....

[@garyaanderson214]

I have worked on rvs and know of the squeeze out of butyl tape.I found a plastic pizza cutter wheel and a little bit of mineral spirits works very well trimming the squeeze out.The plastic wheel wont scratch or cut the paint/coating.

[@ChuckCassadyYT]

That my friend is genius

[@scottbailey2610]

This Old Bus. Love the intro! Great channel.

[@vincentlapointe4273]

You are the best! So cool and informative your videos are! Thanks always good to learn with you.

[@imas2pid80it]

Love watching these videos. More please.

[@b-rok7174]

I was going to try to keep the windows on my skoolie. Now I know better.

[@chrisgentry4427]

Finished watching the video, and saw another idea I didn't think of. I welded in a frame on my bus where there were double windows that would span over the hat channel. Great idea putting a header above. Much simpler and less time consuming, but still gets the same results.

[@danieldzurisin595]

Well done. Well explained. Well demonstrated.

[@bobdart8373]

Thanks for the lesson Chuck its much appreciated

[@connief5154]

Another great one Chuck! 👍

[@joshuaross8565]

Thanks for sharing your hard earned knowledge and experience !!

[@jameswaterhouse-brown6646]

Man you explain things very well ! Thanks!

[@danp762]

Hey Chuck, I like the videos. Thank you for sharing.

[@andyman1982]

I've binged several videos on your channel to help me with my chassis selection and preparation for the whole undertaking. Though it may be a year or so before I'm ready, but I will definitely be reaching out for a consultation when it's time to plan the installation of critical system components (solar, batteries, hot water, etc.). Thanks for providing such invaluable content to the DIY RV/Skoolie community Chuck!

[@ChuckCassadyYT]

Thanks! I'll be here

[@brofessormex]

I'm swapping this week. Good luck.

[@purplegiraffe8194]

thanks for another great video

[@1cosmocat]

Another very interesting video

[@rockford5016]

Missed you, putting up a deck. 4:00 am just finished watching. Another peanut butter cookie show. Love peanut butter cookies and that cookie monster that I become. Gave you a 👍 up and hopefully make the next show.

[@robertbirch4163]

Very informative

[@samh44210]

great video

[@carerealtyco.19]

Hi Chuck! Thank you so much for sharing all of your knowledge in such great detail. It’s an incredible resource. Question: for your window install, I can see that the trim ring clamps over the wood window trim. In a lot of van conversions, I notice that people just install the window first, without a frame, so all that is between the window and the window trim is the metal from the van. Are both ways fine when it comes to the integrity of the window and things operating as they should? Your way seems more professional but are there important reasons for doing things your way beyond aesthetics? Thank you for all that you do! Katie

[@buffalomitch7088]

My son and I love your videos! SO informative! When are the live chats? We have questions ;-)

[@HippieLongHaired]

Maybe use the magnetic welding clamp on the outside of the bus. With one magnet on each side of the window. And a cushion of some kind between the window and the clamp. This keeps the window pressed in place while still allowing the window to be re-positioned. Then the trim ring can be bolted on the inside without having to hold the window nor put any clamps directly on the window.

[@Warp9pnt9]

Another excellent video. Although, I wonder if there's too much thermal bridging around the window? I would probably get IR measurements in cold weather, see if there's enough heat loss to justify further testing, then experiment with various styles of framing, maybe larger air gap between hat channels and window frame, or using a composite frame, with inner, outer, and maybe a sandwiched material (like XPS?). Or maybe even just drill a bunch of holes in the wood to be filled with spray foam later. Also, I'd look for RV windows with thermal panes, or an inner and outer pane separated by an air gap. Anything to minimize thermal bridging across the window or frame. Windows will probably always be the weak spot of any thermal insulation system. But it's an interesting opportunity to improve upon.

[@bmxican1023]

No guard and no handle on the grinder, atta boy!! Get a nice forearm work out in 😂

[@CircaWanderlust]

I came to this video for the window "how to" but let me tell you that you spoke to my soul when you said that leaving the windows could led to mushrooms because after tearing apart our bus to replace the windows I've been second guessing if it was worth the work lol

[@ChuckCassadyYT]

you'll be glad you did it!

[@tcmhammer]

It would be nice for you to do a video of what you would do, if for some reason you had to build a bus without being able to replace the original windows. Thanks your work and videos are both top notch.

[@ChuckCassadyYT]

Thanks for the idea! Though I would never recommend it for full time use!

[@tcmhammer]

@@ChuckCassadyYT I live in Minnesota and plan on building a bus for traveling south for a few weeks each year during our terrible winters. Then maybe after a while doing a raise and installing RV windows. But I totally understand and will figure out the best way. It's just your advice always seems solid.. Thanks for what you do.

[@ChuckCassadyYT]

@@tcmhammer definitely and happy to help! Id suggest just selling that rig and doing another when the time comes. Its so difficult to do a roof raise after the fact!

[@davidstaggs4782]

I have 18 foot 1974 Dodge rv in good shape but the inside needs all redone that my project do you thank that a good project I knew it's not a skooly but I bought it really cheep

[@LiruScarrrbauu]

Esti tare destet ìn tot zinc multam ❤❤❤❤❤❤❤❤

[@waxler2]

“It panes you…” hahaha

[@dockledoo]

I hope you show us all the finished windows before you put in the insulation!

[@colleenbalch328]

Psyched for a "new outlook"! :D See you in the chat, Charlie.

[@chrisgentry4427]

Just curious if you've used the electric metal shears or nibblers for sheet metal cutting? I've not used the nibblers yet, but bought a cheap harbor freight metal shear and it cuts smooth as butter and doesn't have the hot metal chips flying everywhere. Downside is you would still have to change tools to cut the corners as it doesn't turn a radius very well. But not sure if the nibbler would have that limitation. Great video as always. You are quickly becoming one of my favorite channels to watch. I recognize quality craftmanship when I see it.

[@ChuckCassadyYT]

Thanks! I use shears in another video and I love them. My nibbler is good but, I think I need a more expensive one to get better results

[@mkowltra]

you could use the trim ring to trace the exact window shape.

[@kenknaell1290]

Very nice Chuck ! - you deserve a Margarita :

[@sum42guy2k]

Just a hint on a MUCH easier way to cut the corners… you used the whole saw to draw it… instead use the hole saw to cut it using the frame to guide it perfectly (2points of contact between the hole saw and frame)

[@ChuckCassadyYT]

Holesawing a 6” hole through steel like that is something I avoid but thanks for the hint

[@cullenmiller8170]

Great way of doing the RV windows. Do you use insulation between your wood frame and RV window on the inside to fill that small void? Also would there be a benefit to apply adhesive between bus skin and wood frame? Thanks for those great videos.

[@karylm23]

Replaces windows... opening line: "it panes me" 🤣🤣🤣

[@dalejohnson5148]

Hello from Ohio I'm new to your channel

[@Deltro61]

Hello chuck: A bit off topic, but I thought you might be able to provide some tips or resources to installing a window to a curved surface? I have a fiberglass shell on my cargo van, and the outside wall is curved. The distance if I put a straight edge on it is maybe a quarter of an inch from flat. Naturally smaller windows would work better than larger ones in this case, but I think any kind of glass sliding window would bind (If not break) If I try to tweak the aluminum frame to the contours of the curve. An acrylic window might be a better option, but I think they still have aluminum frames. It's possible with some butyl tape I could go extra thick on the ends, and very thin in the center. I don't think it would be quite so attractive on the outside of the van though. I'd prefer to be able to bend something to the contour. Any ideas? I'm sure I'm not the first person to put a window into a curved surface.

[@BuckJones1909]

Another entertaining (keeps my attention) and great learning video! Thank you! The windows on a Crown ‘67 look very different. Do you recommend changing those out?

[@ChuckCassadyYT]

Crown windows are great, I'd keep them

[@BuckJones1909]

@@ChuckCassadyYT Thank you!

[@trustedlocal2988]

Butale tape is the best. That's how older cars windshield is held in.

[@aprilranew1216]

Maybe this is a dumb question but I thought that the wood wasn’t supposed to touch the metal. It is okay here because of the holes in the window that’s for the condensation?

[@Breathwork_Evolution]

Chuck please please please do a video on different types of furring. I am doing them where I’m cutting 2x2 and attaching it to the side of the hat channel up top leaving, a quarter inch overhang below the hat channel. I Started by doing long one by threes from front to back but then couldn’t figure out in my mind how I would attach cedar plank going the same direction. So I switch to doing them horizontal to the bus going left or right. I have never seen how you do it, all I see is the beautiful ceilings afterwards lol. I’m sure there are plenty who would love to see the same. Maybe I could pay to get a consultation from you? Cheers from Souther Oregon

[@ChuckCassadyYT]

Framing video will be happening in the next month for sure

[@Dovietail]

I get nervous about exterior wood trim. Could you do the same mount with aluminum on the outside?

[@nortavon]

I prefer vinyl house windows using a 1"x1" steel frame on the inside that I used on my build. I got the idea from Napp Time .

[@ChuckCassadyYT]

The only thing I don't like about some house windows is they sometimes lack drains in the sills

[@ericdebord]

"How great is the vibe in this bus ! Pretty fun ". That's about the most awesome thing to say . Wow that's an amazing quote that should be on a freaking Tshirt or maybe a slogan for a business. How great the vibe is in Las Vegas, pretty fun ! How great the vibe is in Australia, Pretty fun That's good...

[@ChuckCassadyYT]

Hahahaha

[@ryanlangan1060]

I have some RV style windows in my Thomas from the factory. Do you think I should keep the ones I have? Have you heard of issues with that style? Maybe I should spray the bus down with a hose now that I have the interior panels out - then I can see if there are leaks.

[@rhwinterest]

Hi Chuck. I’m looking at purchasing a shuttle bus. What are your recommendations with changing out the windows? I noticed that you build Skokie’s. Are there any videos that you can suggest where people have changed out their windows on a shuttle before bus. My goal is to keep the windows because of the light and ventilation. I’m looking to build a combination home/store/lab. Any suggestions would be awesome.

[@Budginut]

When cutting your corners, did you every use that hole saw you used for the radius and cut out the corners of with it?

[@cycleoflife7331]

I found cutting out the panel before attaching it to the bus then I use 3M urethane window sealant to attach the window to a painted metal sheet. After it drys I then install the sheet onto the bus. Instead of building an interior wood frame I use flashing and form it to the shape of the window, rivet the ends. Then I foam around it and attach the inner ring. The hardened urethane is strong enough just like the windows on your car to hold the window. Have you used 3M urethane and why do you prefer tape over it, chuck?

[@ChuckCassadyYT]

I've used urethane to attach van windows, it's great. What I like about the trim rings is that all you need to do if you have to service the window is unscrew it. Your method sounds good, we never seem to have the Floorplan finalized enough to precut the windows!

[@davidgathercole6061]

Hi Chuck! I thinking of getting a pusher bus but I don't want a tow car. I want to set up about 12ft. of the bus to carry a car. Can I do this with a pusher bus? Also, How do it link up to the show Gut it? I want to watch you guys rock it!😁😁

[@mc53818]

What do you do for insulation in the corners on the inside? Spray foam? Foam board? Just say screw it?

[@t-moteo9919]

I haven't seen windows mounted in such a manner. With the internal frame being wood. What about the condensation transfer from the sheet metal to the wood. Do you treat your wood window frames with some type of sealant? I would think the frames would rot out eventually. I love the idea of framing in internally as part of the interior structure. Just wondering about the rot. Condensation is a beast in tiny spaces.

[@nicholasphillips5406]

Please reply to this @chuckcassady

[@psofadotcom]

Would using the hole saw to cut the corners with an angled bias towards the corner work? If so, then the only work for the saw is the straight cuts.

[@wesrennells910]

Would it be possible to replace the screws that come with the windows and use something longer to "sandwich" to our new depth whatever that may be for each build?

[@Scoliosisguide]

"i love mushrooms - but not in my bus" 😂

[@dianepetroski4220]

"It panes me" 🤣🤣🤣

[@innerwoven_family]

Do shuttle bus windows have the same issues ? even when seal well and walls rebuilt? The have drains and are single pained 😢but i really would love to know?

[@DustinAuman]

Chuck, I just got RV windows for a bus that already had a roof raise. Im having trouble finding whether I should paint the exterior before installing the windows. The sheet metal has some slight rust. Should i clean up the rust and paint a primer before installing the windows, or just clean up the rust only before installing them? Thanks for any help!

[@tylergould6789]

Chuck I’m curious: when making your frames for these do you take into consideration the thickness of the sheet metal and the butyl? About to start making my frames like this

[@ChuckCassadyYT]

yes! i would plan on just about 1/16 if you use 18ga

[@ourbustheroci4052]

I love the idea of framing in wood first. I did our large back window with 1.5" steel tubing as I needed to reinforce since the entire back was cut out. What would you do say on the sides if you needed to cut a hat channel? We have some larger 2'x4' windows going horizontal up near couch and dinette. I will cut hat channels and then use some 1.25" tubing to frame them out. How would you do it? Thanks!

[@ourbustheroci4052]

We also do our windows before sheet metal. I like how with the smaller windows you can do it after and get the frame flush. Like you said many ways to skin...

[@ceceespejo5164]

I watch your video, install a window. I am new here, I planning to buy old Rv but the windows are old and I planning to put insulation windows. I dont know that's how is call 😊 any way, i need to watch your videos to see how you do this project. I have a question, if I want to have more light coming inside which that's what I want; can I cut the rv walls bigger?

[@iberg01]

Question, instead of drilling 8 pilot holes, why not just drill 4 with the hole saw you used to mark the radius?

[@danieltracy2261]

“It panes me”, could of been a great window complaint pun. Wasted opportunity 😂

[@ChuckCassadyYT]

I've made that pun many a time. It never gets old!

[@babygal9702]

Hey what if you want to install the larger window that doesn’t fit between the metal frame, how would I go about taking that out, is welding the only option?

[@jimhuskins8506]

How much light does it take to make a ton?

[@jiGGaWHAAAA]

Chuck is THE MAN!! Curious why most people DON'T change out their driver's window for an RV window for the same reason we change out all the other windows? The only thing I can think of is that we don't want tinting for legality reasons, or maybe some buses already have dual-paned windows in that section? What am I missing?

[@ChuckCassadyYT]

hahaha thank you. i left it because i was going to need a very custom window to keep all the visibility i wanted and i prefer the original window. nothing is perfect, espcially in a bus but ive never been totally satisfied with the times we've replaced the driver window with an RV unit.

[@jiGGaWHAAAA]

@@ChuckCassadyYT Fair enough. Today I'm skinning that section back in after having done my roof raise; I guess I'll follow your lead and keep the OG window. Thanks for the reply!

[@Dovietail]

Aesthetically, men NEVER put in enough (or large enough) windows. Show me a bus with replacement windows, and I'll tell you the sex of the designer.

[@kelleyransom3616]

so my bus has a rounded wall… any suggestions for how to keep a seal, or how i can find new rounded windows?

[@kingwizkhalifa1]

👍👍

[@bhsband4546]

Does anyone have or could provide the exact measurements and directions to build the wooden frame please?

[@silvestrelorentemartinez4622]

I need two windows for my school bus, do you have any for sale?

[@philipwheeler7317]

Question. That works for new walls that you made. Is there any way to simply remove the existing windows from a bus. And install a panel, much like your window panel to hold the window. And simply put RV windows in the old window slots. Sorry if that question is worded stupidly, but basically not redoing the whole side of the bus just replacing the windows. Thanks.

[@kaelamoscariello759]

What size is this window?

[@ki6uoc]

Do you have any experience with acrylic RV windows in a bus conversion? The folks over at Ambition Strikes used a number of them in their camper build and they seemed to like them. Do you think that they're worth it over an ordinary RV window?

[@ChuckCassadyYT]

I prefer glass almost always

[@user-uk4mr1ku2c]

Can i install impact windows on my skoolie?

[@wallacegrommet9343]

Butyl sealant doesn’t like strong cleaners, like alkali solutions, or solvents like mineral spirits

[@ChuckCassadyYT]

mineral spirits is my go to

[@brofessormex]

Ok im at this stage. I have an old 69 chicken bus from Mexico

[@dchubb42]

The biggest issue I've had in the past year + searching is finding the right size windows. With Covid, it seemed like everyone and their cousin bought all the new and used replacement windows available out there. Right now they are coming back into stock and I'm looking at taking an 8+ hour drive up to Michigan to get windows. So help the community out and let us know where we can source them (part numbers?) Have you tried one of those sheet metal "nibbler" to make your window cuts?

[@ronaldsnider8078]

I brought a nibbler and love it Great use for cutting metal in my bus or cutting side metal when I put my back porch on. Monkeyvaroom

[@ChuckCassadyYT]

I like nibblers quite a bit!

[@afucanada]

Hi Chuck! Is it possible to install regular /common house windows on a bus? Or is there any reason why I shouldn't even try?

[@ChuckCassadyYT]

Possible and people do it!

Chuck, I followed your example to the letter (really impressing my wife in the process), but I have 2 questions: 1. My windows came with a thin rubber basket where the butyl tape would go. I'm not sure how well it would stand up to bus life. Scrape & replace or leave as is? 2. Is there any additional adhesive you use to hold the frame against the skin other than the window mounting screws? It seems like a lot of weight for those little puppies.

[@ChuckCassadyYT]

i usually ditch the gasket, and once the windows are in, i will then finish the interior framing and make sure it ties into the window frames

[@matthewthomas5370]

Hi Chuck! Quick question, I bought my windows from a surplus RV warehouse and they did not come with the mounting screws. How long were the screw’s you used? It looks like the have to be petty short.

[@ChuckCassadyYT]

These are 3/4

[@r8edrv4fun65]

It "panes" you?? 😆🤪

[@scottifly]

RV windows are not optimal in my experience. The weep holes become overwhelmed when it rains hard so the window track frame fills with water which then spills over and runs into your bus. This is especially true when the bus is not parked in a perfectly level spot. Manufacturers have opted not to change their RV windows and frames so the problem has persisted for decades.

[@donaldgulledge729]

Where can a guy buy old school bus windows like the ones your getting rid of? Would like to get a bunch cheep to use in green house builds. Whos scrapping out the parts?

[@dockledoo]

Can you install the windows vertically?

[@ChuckCassadyYT]

if the window is designed for that, yes