So, I journeyed home and decided to tackle the windows. Six hours later I had them installed.
I have to say, I knew it would not be easy to cut the aluminum doors to fit the windows. I was EXTREMELY careful. I started by using my cardboard template.
I put the window in place and was immediately heartbroken. I had cut it too big. I couldn't understand how this could be, the template was meticulously made and I measured three times. It turns out the radius of the window was slightly larger than the piece of aluminum that sandwiches through the door. I had used the wrong part of the window as my guide. (Notice the teeny tiny light coming through the top right corner of the frame.)
I immediately was crushed. How could I have been so dumb? I was beside myself. I thought about my options. I considered making new doors out of wood; ordering bigger windows; etc. none of those options appealed to me so I sat down and sulked. I decided to hope something at the hardware store would inspire a solution.
I went to the hardware store and looked at every type of weather stripping, Velcro, plastic I could find. Nothing would work. So I wandered the aisles trying to think outlet side the box. Defeated, I drove towards home. Then I had an idea; make a gasket, but with what?
I steered towards the bike shop. I purchased a bike inner tube.
Twenty minutes later, I had made my own gasket with the tube. Another trip to the hardware store for some adhesive. I was able to split the tube and work it over the aluminum where the window would sit. I was then able to install the window in a way that provided just that teeny bit of difference I needed from my 'mistake.'
It took a couple of hours to trim the other window. I went through seven metal scroll saw blades all together. I went to the bike store and bought another tube. I was able to quickly make another gasket and install the new window.
Now, the windows are installed and the doors are back on the teardrop. What started as a heartbreaking 'mistake' ended with a unique customization! I'm hopeful when the adhesive sets up that I can add a little more silicone sealant to the gaskets to ensure that they are watertight.
The cabin is already much lighter with the windows in place. I feel proud of my problem solving skills, for today.
