Need advice for cutting window openings in box.

[BravestDog]

This is a Grumman Olson aluminum skinned box that measures 8x14'. The forward wall is FRP (fiberglass reinforced plywood). The side walls are aluminum sheating with "z" studs every 16". The rear wall is a roll up door.

The ceiling is aluminum sheating with joists every 24".

I need to get fresh air and some light into this box.

Any suggestions for skylights, side windows...?

The roof is crowned for proper drainage. approx 1-2-3" higher than the sides.

Does anyone know how much I could cut away on the front panel for installing some windows or skyights here?

http://truckconversion.net/photopost/showphoto.php?phot...&size=medium&cat=500

How about the interior? Would I have to weld a window opening by cutting out unwanted wall studs and then installing a header?

http://truckconversion.net/photopost/showphoto.php?phot...edium&cat=500&page=1

http://truckconversion.net/photopost....php?photo=718

Any suggestions?

[KAYE RIVERCITY]

DO NOT CUT THE FRONT OF THE BOX OVER THE CAB....wind pressure and rocks/branches will give you a supprise on one of your camping trips....cut only the sides and maybe the back door.. Get a router with a carbide drillblade similar to a drywall router blade....it pierces and cuts both-looks like a drill bit with tiny blades where the drill flutes should be...it cuts aluminum and is about 1/4" in Dia......lay out you jig and tape it into place-I use 4 sheet matal screws one in each corner to keep it from slipping-use goggles and go at it...if you cut any studs inside you can weld them[yuck] or use VHB 3M tape to repair them with commercial pop rivets/sheet metal screws/new 3M glue like liquid nails....I use tape/SS pop rivets cuz I'm lazy....makes a very solid frame...remove the cuttings[very carefully and cleanly] and install the rubber and soap the glass and slide it in-install the round bead part of the window gasket-use WD 40 for that and a screen tool....your done! I try never to cut into the top if it all possible....most leaks are in the top because of expansion and vibration/tree limbs.....geofkaye

[Kirk]

We have the same issue as you. We are just going to cut a hole in the side of the box and make a header for over the top. Probably have some 1/16" Z bar custom bent to make up a header and a rail along the bottom. We will probably weld it in becuse we can. The key is to make sure you keep the side good and rigid.

[KAYE RIVERCITY]

......insulate the Z bar or channel or even the rectangular tubing with a thick layer of something that won't conduct heat....very important not to warp the aluminum or even the FRP for that matter with too much heat......and as usual-watch for fire and sparks.....geofkaye