Windows in doors/ i messed up!!!

[Forrest747]

Ok I admit it i messed up. in cutting out the holes for my windows in my door. the jigsaw blade went at an angle and made the opening at the back way to big. I should of listened to wife who said use the router. ( She was one smart cookie) anyhow the damage has been done. I am also in a pickle that even if i hadnt messed the cut how to attach these windows to the door.

So was thinking of just scraping the idea all together i have other windows in Charley and just fixing the doors, ie cutting it out square and patching the hole closed. i hope i am making sense. Pictures to follow later.

[WesGrimes]

I have fixed some situations like this by mixing the sawdust from the cut with gorilla glue into a putty. Use the putty to build the over cut area back up. Let it dry overnight, and sand down to size.
Its coloring and staining will be similar since the sawdust was from the cut.

[eamarquardt]

There are lots of approaches to fixing a minor boo boo. You can add a bit of trim to the inside and or outside to cover the gap, square up the hole a bit and add a bit of trim to close up the opening, use some L shaped trim to close it up a bit, etc.

Don't get discouraged and give up. Take a break, have a cool one or two, and you'll figure out a way to make it look good. And if anyone ever questions the extra trim, say you did it deliberately and stick to that story!

Cheers,

Gus

[Miriam C.]

Fixable. Letmesee.........you can mix epoxy and sawdust to build the edges up. That will waterproof it too. You can also make a frame around the inside of the window or buy a bigger trim ring.

[doug hodder]

I'd think that you should plop the window into the opening and then decide whether or not you messed it up. If if fills the opening and there are no gaps...it's an easy fix, as long as you can seal the window on the exterior and fasten it. If the gap is on the interior...then some trim will hide all your issues. I always seal the edges on the ply, but some trim, and curtains will hide a multitude of sins. Doug

[Rlowell]

It also depends at which angle the blade sent. Sometime you can go to the other side and square up the cut and then use the above methods to fill the gap..if any. I did that on my walls with a bad blade on the circular saw. Worked out great.
Rod

[Forrest747]

Been looking at buying my CPES and reading closely i came accross Layup & Laminating Epoxy Resin where they say to mix with the saw dust and will be almost like Bondo. Thinking getting a small can of this stuff and making the repairs that way. Am I heading in the right direction?

[Forrest747]

Here are some pics i took. I am going to try to mix the epoxy with some wood flour or sawdust and see if i can close that gap in some. Also has anyone attached the window by screwing through the outside trim piece. with buytl tape behind it. I am afraid to drill through the side and breaking the glass. The windows came out of a van.

[john]

The windows on my second build were bought on Ebay for very little as they had no trim rings for the inside.

I drilled holes around the outer edge and screwed them in with SS screws.

I imagine your windows are similar and if you keep your screws on the lip that rests on the surface of the door it should work fine.

[Forrest747]

This is what I am thinking i will do. Screw it through the trim with the window sealant and fill in the holes.

[timlsalem]

I had a round AC plug inlet for hooking shore power up and I cut the hole bigger then I should have. To fix this problem I took another piece of wood and cut it round and a 1/2" bigger then the previous hole and then cut the correct size hole in it and installed it over" the too big of a hole". Worked perfect and looked like I had planned it that way. I think, from the pictures I saw, epoxy and saw dust would work for you.

[parnold]

I also attached my windows and doors with ss screws through the outer frame. I used butyl underneath, and then also sealed with clear silicone for double assurance.

I also agree that the epoxy/saw dust should work fine.

I was so anal about not cutting my holes too big, that I spent hours sanding the openings to get the windows to fit. b

[Micro469]

I see it looks fine on the outside. The inside shows the gaps. But it also looks as if you dont have the inside skin on yet. Is that right? If so, you don't have a problem. Just make sure you cut the hole in the inside skin the right size, and whatever is inside the door is completly hidden.

[Forrest747]

Micro you would be correct i have not skinned the inside yet. THe plan is to cut the hole inside and trim it out. it the attaching the window to the door i am having an issue with. Did not come with a clamp ring or anything like that. it was designed to just pop in the van from what i can tell and i havent been able to find that set up. So drilling holes and using screws or bolts to attach is the way i am going. this is fun to figure out.

[rladams39]

if your worried about busting the glass tightening the screws, just do it with a screwdriver, and be careful to not over tighten them. If you use butyl tape just tighten enough to get a little compression on it, the stuff seals really well....