LET THERE BE LIGHT!
Hey Gang; It's been a while since I posted (pimped my 19RR). Today I got brave enough to cut a hole in my door and install a window. I noticed that after 2010, FR no longer put the solid frosted glass windows in the 2011 and 2012. I found a window on Ebay that I got with shipping for under $50 (turned out it was slightly used... but that's OK), so here are some pictures of how I put it in. I took 8 pictures and they only let you post 4 per posting, so I will do this in two posts.
Here is what the door looks like on the 2012 19RR.
Then I marked where I needed to cut on the inside (aluminum side of the door). I was surprised that the difference in the outer frame and the hole you cut is only 0.75", or that you have 0.375" of overlap on each edge of the frame. The other lesson learned was I was surprised how hard it was to get the pencil marks back off the white aluminum door once I mounted the window where my construction lines went beyond the frame. I would have thought pencil would have erased off easily.
Then I put painters tape on either side of my cut line so that the vibration of my electric jig-saw didn't rub the paint off the door.
In the picture above you can see I drilled 4 holes, one in each corner with a drill with a metal bit larger in diameter than the blade on my jig-saw. This was so I had a few places to stick the blade of the jig-saw through to start cutting in any direction. I was surprised how thin both the aluminum and the fiberglass sheeting was in this door. Most of the thickness is just solid styrofoam. I guess they are not kidding when they say a mad grizzly bear could claw his way into your camper if he really wanted in!! Here is what the opening looked like once the hole was cut. This was when you start thinking "man, I hope I did not cut the hole too big!!!"
Well that's the first 4 pictures. I will continue on a new posting.