Cutting window openings in a composite body truck camper-Ford Maverick build.

[@gf2e]

Pretty interesting technique. I don’t have any experience with this specific problem yet. 2-3 years, I probably will. :) You indicated that you were happy with the circular saw cuts. What about cutting 3/4 of each of the four sides with a circular saw? If that went straight through, then you’d have four perfect edges, which would let you line up the template perfectly on the other side. To make a drill go straight, I am imagining an L shaped T slot structure that would go against the panel you’re drilling, along with a bracket that attaches to the drill and that slides along. Something very similar to one of those portable drill presses, really. I will have to think about that when it’s time for me to start my build.

[@steveogilvie5203]

The reason I didnt use the circular saw on the sides of the windows was that I wasn't that comfortable holding it up in the air. So it was just easier to do it all with the jig saw. Doing the second window I drilled the same amount of holes but since I used a solid template I just put 2 bits through along the top edge and then held the template against the bits and just drew around it lined up with the holes. The problem with the jig saw trying to cut both sides at once with this material is the bit starts to bend as you go around the corner and then it just ruins the cut on the other side. The whole process would be a lot easier if the windows came with a paper template. Especially these acrylic windows that have little room for error. All good sugestions thanks for commenting.

[@steveogilvie5203]

Just because I have never figured it out I came up with a cost per square foot for the composite material I use. For a 1" thick sheet of XPS based Filon sandwich the cost to me is 7.07 CDN per square foot.

[@bradleylacey836]

Hey Steve, really interesting videos. I am looking to do the same. Im down in Kitchener. Where are you getting your composite panels from?

[@steveogilvie5203]

@@bradleylacey836 I make them myself using Fylon fibreglas and styrofoam. I usually buy the Fylon from RV surplus places like Bontrager's in White Pigeon MI. There are some videos where I show how to make the material.Thanks for the comment.

[@steveogilvie5203]

kzbin.info/www/bejne/rqulk6uHn7Wbd6s Building a 4x8 sheet of composite material.