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Old 03-21-2016, 08:48 AM   #611
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Nice work!
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Old 03-21-2016, 02:28 PM   #612
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I hate how long it takes you to get new pics posted, I love how you take your time and engineer them correctly and give us all some help on your way through with this!!

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Old 03-21-2016, 09:41 PM   #613
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Carving windows

Some photos of cutting window holes. You can see the three inches of foam make for a daunting trim ring. As far as I can find, rv trim rings this deep don't exist.

Some thoughts on things:

The notch to access the fasteners for the window, just enough to get your finger in there to hold the nut. When its "done", as in I don't want to take the window out and its sealed, I'll stick a couple strips of foam in that crevice, or maybe some expanding foam.

The interior metal facing the foam panels is bone dry. This reaffirms my thoughts that bonding the foam to the steel is unnecessary, and in some cases bonding might trap moisture.

There is enough elasticity in the foam panels to move the cutter head of the sheet metal air nibbler.

Cutting the foam out was actually harder and more time consuming than cutting the metal out.







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Old 03-21-2016, 09:43 PM   #614
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Thanks, I try to go as fast as I can but there are always a lot of things that compete for my time.

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I hate how long it takes you to get new pics posted, I love how you take your time and engineer them correctly and give us all some help on your way through with this!!

-Doc
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Old 03-21-2016, 10:43 PM   #615
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Is that a "Nibbler"?
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Old 03-21-2016, 11:10 PM   #616
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Yes, it works great.

It will let you cut the wrong line in a hurry, so better be sure you know your cut line. What's nice is it doesn't really grab the material, you have to push it into the metal.

It also makes thousands of tiny crescent shaped caltrops that fly everywhere. Wear a safety shield and clothes that shed metallic sharp chip.

Other than that, it would take just a minute or two to cut a hole nearly any shape in the bus sheet metal.
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Is that a "Nibbler"?
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Old 03-21-2016, 11:25 PM   #617
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They are very good tools, you can get them at harbor fright for under 30.00 and if you catch them on sale for about 10.00 be warned they do use the air, so not the best tool for a pancake compressor. You can make about any design you want, they do has there limit on metal size.
I might also add they are small and very light weight. In my use of them I had a harder time with the air hose
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Old 03-22-2016, 01:48 PM   #618
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I used a harbor freight air nibbler for some of my windows... the punch kept breaking off though. I went through 3 of them I think. The package said up to 16 gauge steel, and I was cutting 18 gauge. For what it's worth, it worked well while it worked.
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Old 03-23-2016, 04:26 PM   #619
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I picked up a hot knife from harbor freight, I should have done that when I started working with the foam. Cutting does make a lot of toxic gas so I do it on the outside.

Cutting the metal, then the foam is a pretty simple operation. Making the trim ring insert will take the most effort now.

Attached a comparison of cuts from hot knife vs serrated saw.



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Old 03-23-2016, 07:42 PM   #620
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Cool idea, think if you were careful enough one could cut lines in the roof insulation so to mold the corners instead of using a circular saw at half the depth of the foam?
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