More Windows Covered! | Bus Conversion

The last few days I have been working on covering more of the bus windows.  I did this on the inside and not on the outside.  Sometime in the future I may go ahead and cover the outside of the windows with metal.

This is what I did.

First, I removed the wood trim that surrounded the windows I wanted to cover.  I ran them through a table saw in order to make a notch in the wood.
 

Next, I reinstalled the wood trim strips.

Trim with Notch

Installed Trim with Notch

Then I installed construction foam over the window and in between the wood strips.

Construction Foam Installed

Then I cut 1/4" oak plywood to fit each opening and stained and varnished each panel.

After they were dry I installed the plywood panel over each opening.  In all I covered 7 Windows.  In doing it this way I was able to avoid having to cover the exterior window openings with metal because I didn't have to remove the existing windows.  When I am ready to cover the exterior with metal I don't have to remove the windows either.

Front Dinette Window Covered

Rear Dinette Window Covered

Front Kitchen Window Covered

Master Bedroom Passenger Side Windows Covered

Master Bedroom Drivers Side Windows Covered

After all the panels were installed I applied silicone to all sides of the panel to insure and good air tight seal.

My reason for doing this was to increase the energy efficient of the bus.  It should stay a little warmer in winter and cooler in the summer!

UPDATE:  I had someone ask what it looks like from the outside.  You can't see the foam insulation from the outside because of the dark tint on the windows.  I will post a pic soon.