Sienna Van Conversion- Window Screens

In our last installment about the Sienna van conversion we discussed installing the bed. Little did I know, that was the easy part. The sliding door windows needed screens, and I wanted to put in cabinets along the back windows. At least I didn’t tackle anything challenging! This post is about Sienna van conversion- window screens

Make a Template

I figured that I could use a piece of corrugated cardboard to make a template, cut the frame out of a sheet of plywood, staple the screen to the frame, and install it in the window frame. Easy. 

Not so fast, dude.

I quickly learned that although starting with the cardboard was an excellent idea, the cardboard cutout only approximates reality. If you learn nothing else from these posts, please remember that. Also, the windows in my van do not go down all the way. You can’t template the curves at the bottom of the window very well.

I cut out the cardboard as best I could, put it in the window. The fit was close. I bought a half-sheet of the thinnest plywood Home Depot had, cut the frames, and stapled the screen into one of them.

Live in Three Dimensions

It didn’t fit. I was living in a two-dimensional world. The window and frame are curved. I needed to be in three dimensions, but didn’t know how to get there. I slept on it. 

By morning I realized that someone else surely had solved this problem. All I needed to do was search the ‘net and find their solution. My old buddy Bruce Parks had a youtube video about it.

 

 

He and I had solved the first parts of the project the same way. After he finished cutting his frame, he “added material” to make his frame match the curve of the window. He did not say or show how he did this. His video wasn’t much help as far as that went. He also put foam weatherstrip around the outside of the frame to seal it better. That flat out did not work for me. I made the Ace hardware store people happy by buying every kind of weatherstrip they had.

Bruce Park made me realize I needed thicker plywood. Being a homeowner, I had what I needed here already. I cut out and sanded a couple more frames, tried fitting them with the weatherstrip on the outside edge. ARRRGGGHHH!!!

Become an Expert on Weatherstrip

Susan and I went back to Home Depot to examine the weatherstrip selection. We got some vinyl weatherstrip. I stapled it around the inside edge of the frame, with the vinyl “lip” extending out. This filled most of the gaps. Judicious use of foam weatherstrip filled the rest.

It’s an imperfect solution. But the screens are in the windows. I believe they will keep most bugs out. For now at least. Until I run into someone smarter that me!

Thanks for reading about our Sienna van conversion- window screens!