Alpine window cut outs/template

Hi guys

I've purchased masai 4x4 alpine windows with cut out template. Then Cut out the roof bang on to the dimensions with a jig for accuracy using laser cut peices of wood.

Come to fit the windows today, absolutely impossible to get the windows in the seals. That's without the filler strip. And 2 blokes.

On inspection, the glass measures 120mm wide. The cut out masai provided states 128mm wide cut out. Then looking at the cross section of the seal, its core which the seal sits in, and pushes onto the roof is about 10mm, so both top and bottom equates to 20mm.

So if im not mistaken, masai's dimensions are wrong, and the roof needs virtually 140mm width cut out. (120mm glass, 10mm seal cross section top and bottom).

Can anyone help confirm the dimensions, and has anyone had any success with masais template? So far not impressed with that company. Any help appreciated

I can’t help unfortunately, but I am interested in the replies as I intend fitting some used ones.

Before you go cutting I would check they sent the correct seal. I fitted some windows into a Dormobile roof and the size difference was 1/4 all round for quite a big seal. Your 4mm may not be far off. !0mm all round seems a lot. I would also say if its the type that has the filler strip buy the tool. Here's some info:
https://www.sealsdirect.co.uk/shopping.asp?intDepartmentId=4#27

I fitted some, not masia but genuine LR ones, into a 90 about 20 years ago. I remember it being a bit fiddly but easily doable with 1 person so obviously something is wrong with yours, sizes, seals or something.
I seem to remember using taped on paper templates?

I made my own templates with masking tape and a marker pen

Thanks everyone. Appreciate your responses.

Marmaduke

Marmaduke said:

I made my own templates with masking tape and a marker pen

Click to expand...

Can you remember where you got the dimensions from mate? Had a look at your thread, did they come from masai?

ONE LIFE LIVE IT. D90 said:

Thanks everyone. Appreciate your responses.

Marmaduke


Can you remember where you got the dimensions from mate? Had a look at your thread, did they come from masai?

Click to expand...

I measured the thickness of the seal first ( I think mine was 6mm). Put a load of masking tape on the roof where you want the glass to be ( apparently there's a specific place if you want a roof liner). Tape the glass in place then I seem to remember getting a piece of dowel from bnq the correct thickness of the seal and putting on the edge of the glass to use as a template. So I ended up with the size of the window plus 6mm all the way around.

Looking at the seals the most likely sizes seem to have a "web" of 6 or 6.5mm.

Thanks guys.

I'll be honest I bought the kit second hand and totally un used. I think I need to get in contact with masai and find out what's going on.
This glass is pilkington which I believe it OEM, So sizing should be fine. The seals on the other hand are britpart, so they could be wrong, despite being the correct part number.

Just an update guys as this may help someone.

Spoke to an incredibly helpful chap from masai4x4. He confirmed the dimensions were correct on the template I have, as was the window the correct one.
The issue was with the seals, BRITPART CR*P strikes again!!! The cross section of the seal is 10mm on the inner core, and it should be 5mm!!

Thank god I didnt cut the roof out to suit the inferior seals, and then I need replacements a few years down the line and the roof is cut out too big.

Enjoy fitting those, nearly snapped my fingernails off a couple of times. Fairy licksquid is you mate

...oh and those nylon pry tools

If you do not have a filler strip fitting tool, I used one of these to fit the filler strip when I replaced my seals, nicked it out of wife's draws. Which was a strange place to keep it.

Don't know if it would make the difference you have experienced but it isn't just the incorrect seal is it?

302177 for 5mm glass.
DBF500030 for 4mm glass.