Took some phone calls to get best price. Purchased through an auto body shop. CR Lawrence won't sell direct to the public, and prices varied quite a bit between different window and glass shops.
There is no guess work in determining where to cut the windows. The inside of the van shell has the outline already to go. Here you can see the dimples I punched to show where to cut on the outside of the van. The cut is easiest on the outside, as there is too much of the frame in the way to cut from the inside.
My friend Doug, helping with the cutout. Installing the windows is a two person job, one to hold the windows on the outside, while the other person fixes the clamping collar and inserts the screws. Both people help to align the window in the opening prior to tightening it down. When cutting out the window, it is easy to tell if you are going off course, because the cut goes from one layer to two layers of the shell, and the cutting gets more difficult.
The window opening cut out. The tape was used to prevent scratching the paint around the window cutout, and to trace the outline of the window to be cut. An angle grinder is also handy to have in case you need to trim the opening a bit. Be aware, there will be lots of metal shavings from the cut. Either mask off the interior side walls so the shavings don't get down at the base of the wall and rust, or be really diligent in the cleanup.
Picture of the window profile, showing the seal that pushes against the van body and creates the water seal. No silicon or sealant required. Simply sandwich the window to the van shell using the interior clamping collar that goes around the window and insert the screws.
Here is a picture of the inside of the van prior to the window installation. The outline of the windows is very clear and easy to trace. The two vertical stays in the middle of the window cut outs are cut away when the opening is cut. Apart from cutting the stays, there is only one layer of the skin to cut, so it is easy to stay within the cutout, the cutting gets harder when you wander into the double layer.
Simple tools used to show the outline of the window through the van shell, a hammer and a sharp punch works best, (A blunt one would cause the paint to split too much). The whole process is actually quite easy, I think going into it, the hardest part is punching the outline and cutting into the shell of the van. A bit nerve wracking at first, hoping you don't make a mistake!
If you look close, you can see the dimples in the van skin, under the tape, which shows the outline of where to cut. I used a felt sharpie to mark the line to follow with the jig saw. Make sure you use sharp blades, I used one blade for 2 windows, then it was replaced with a new one.
Here is a picture of the opening after the cutting. This shows a gap between the two layers of the van shell, and the bare metal edge, which I filed smooth and painted. The window should be dry fit at this stage, in case any extra trimming or grinding is required before prepping the opening.
Here is the silicone I used to fill the gaps in the window opening. (No picture of the Tremclad paint though)
Final window opening prep prior to window install. I filed off the sharp edges after cutting the opening, painted the bare metal with a Tremclad paint and filled the gap with silicone
Final Product - Passenger Side ... Woohoo, looks good if I don't say so myself. The whole process took about 6 hours for the four windows, (3 on this side and one on the driver side). The paint and silicone dry time took the bulk of the time. I purchased the windows with the awning style openers. The middle window doesnt have openers to avoid a possible conflict with the sliding door!