panel van conversion using bonded glass

[hollow]

has anyone successfully installed bonded glass panels as an alternative to cutting in more traditional rubber sealed window units ? i'd love to see some pics if there are any members who've done it. i like the idea of it, as it will probably lead to less water ingress problems in future, but unlike more modern vans the t25 panel van body does not have a panel recess to make it look as neat... and this is my reservation.

I may consider cutting in a caravelle window opening and fitting a bonded glass panel into the return.. anyone see any problems with this?

[scottbott]

have thought that bonded glass would look good but never seen one done,be interesting to know

[kevtherev]

I too have researched this and found that most bonded glass fitters have intimated that the T25 body shell flexes more than modern vans.
Then after finding the right glass with the flexibility it has to be cut and fitted.
there is plenty of room for a bonded panel, but inside the van it would look ridiculous so that would have to be addressed.

[hollow]

I had not given any thought to the flex issues.. In your research kev, had you found that glass fitters that were prepared to do it would not issue a warranty?

Would there still be problems with interior trim around the window opening if tin caravelle window surrounds were fitted internally?

[Plasticman]

Technically well doable, be a nice little project but would it actually look right?
mm

[kevtherev]

I had not given any thought to the flex issues.. In your research kev, had you found that glass fitters that were prepared to do it would not issue a warranty?

Would there still be problems with interior trim around the window opening if tin caravelle window surrounds were fitted internally?

No warranties offered.
yes some problems because the bonded glass would be 20- 25mm from the frame.
As mike says it's not impossible but it would be an expensive experiment should it fail.
You would also have to consider the front windows as they would look very odd.

best way would be to use a tin top panel van and have the windows cut, where a panel van would flex less as the roof is in tact

[CovKid]

Hate to say it, but this could seriously invalidate your insurance. I've no idea how an insurance assessor would view it but it all seems a little questionable without some engineering validation behind it. I like the concept, but wouldn't fancy the implications should things go wrong.

[Plasticman]

Nah. no problem I dont think, youd have to make and fit a support frame within the panal etc, be far stronger than a panalvan with a hole chopped in and a bit of glass in a rubber seal. or folks chopping roofs out and making into poptarts, far worse is done including lethal repairs,but I take your point and it would have to be done correctly .
also the bonding glass would be fixed using a flexible sealant/adhesive,
mm

[hollow]

I welcome all your views chaps.. Thanks.

I am looking to fit a multi van interior, or maybe some custom panels from Newton commercial.. Obviously the trim that goes in will need to co-ordinate with the set of the window, and i see that the bottom of the window frame which the trim panel uses for fixing will be the biggest issue internally. As has been pointed out, there will be a 20mm variation in the line of the window glass, if glass is bonded directly to or set to line through with the exterior bodyline.

I guess mm that the internal support frame that you speak of can be designed to take up this 20mm so all trim support metalwork lines through as well?

There remains a question as to how it looks aesthetically.. But I think setting the glass into a caravelle window rebate remains the best option, rather than fitting glass onto the panel from seam to seam. Any other thoughts?

[Plasticman]

No. if you tried bonding the glass straight to the outside of the van it would look a bo****s, you would take a panal van side, cut a rebate then fabricate a reccess panal to go on the inside and be welded, this would be sized to accept a glass and its respective bonding and would have a finnished surface that was in line and flush with the outside body, relativley easy to do,
as for the inside then thats simple wood butchery and no great problem either
if you cant do it to replicate an as manufactured one then dont do it,
mm

[hollow]

My plans here are totally scuppered by a void of glass suppliers.. Does anyone know anyone who works in toughened glass who can make a custom glass panel for a non-exorbitent price? Otherwise this is dead in the water.

[kevtherev]

make a custom toughened glass panel for a non-exorbitent price?

I would think any bespoke glass panels will never be non exorbitant.. casting a glass panel is done mainly by machines, and machines don't do one offs
However, I looked at similar contour vans (as flat panels would look ridiculous) with over size glass to remove and get ground to the shape I needed.
Plenty of donors... but no takers on the grinding.. it simply isn't done outside the factory. I have found.

bang-bang... what's up with that duck?

[Plasticman]

we used to get front screens (laminated) cut down to fit the front of racers (peugot screens)occasionally they would break but this maybe be to do with s/hand glass that may have had chips etc..but glass cutter and ,, well search the net on cutting laminated ,its not surgery.
mm

[hollow]

I thought about getting a piece of laminated toughened glass cut to size but was abruptly told that I would be a millionaire if I could do it, as toughened glass invariably shatters..

[CovKid]

I've lost count of the radical ideas I've had that were scuppered by cost or lack of infrastructure. Then you get some ass who defaces or breaks it and you're well and truly up the creek. Bit like flip/flop or candy apple paint - looks great but one scratch and you have to raid your savings to put it right again. For the vast majority of us, this aspect of any transformation has to be first on the list unless its a vehicle that only comes out of the garage for shows and then I'm not sure its really worth it.