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Sat Feb 11, 2012 10:47 pm

I've put in my time searching for this procedure and now look to you for guidance...
I'm about to purchase the GW skylight kit for my new 83.5 Westy and am a little nervous about sticking a blade through my roof. any suggestions on tools and procedures - links and photos would ease my nerves...

Thanks! and on a side note, how do i get my vehicle types at the bottom of my post???

THANK GOD FOR THESAMBA

Sat Feb 11, 2012 10:59 pm

I would put some painters tape down first and lay out the out lines you want to cut. Measure 3X and cut once.

The bottom field is called your "Signature". You can add your own content in your profile.

Sat Feb 11, 2012 11:11 pm

Signature test...

Sat Feb 11, 2012 11:12 pm

Sweet that was easy, thanks!

So, what tool would you recommend to do the cutting??

Sat Feb 11, 2012 11:25 pm

Jigsaw. Maybe a fine tooth sharp blade. Cut it on the small side and use a file to hand fit it.

Sat Feb 11, 2012 11:38 pm

When i cut the hole for the skylight I used a jigsaw, metal cutting blade (forget the tooth count), and set the saw for straight up and down stroke. I did have a go with a Rotozip on one section. Worked ok but not as well as the jigsaw.

Be sure to tape some plastic sheeting on the inside of the roof to catch the dust if you are doing this with the roof on the van.

good luck

alistair

Sun Feb 12, 2012 12:44 am

I used a jigsaw blade with carbide grit on it. When I tried regular jigsaw blades, they went dull within about a minute.

Stephen

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Sun Feb 12, 2012 11:45 am

I use this tool
in an air hammer to cut the openings for our tops. Does a nice, neat, non-sharp cut. Easy to control and no metal filings all over the place.

Sun Feb 12, 2012 4:04 pm

:bay_blue: I think he is trying to cut fiberglass ! :D

Sun Feb 12, 2012 4:33 pm

OK - then - I guess I kinda thought he was putting a skylight into a vanagon roof. In the case of fibreglass - a variable speed jig saw - seems there's a "sweet" speed for every fibreglass product. Do tape and cut through the tape for your cut lines to avoid chipping etc.

Sun May 20, 2012 7:37 am

We started making our single layer skylight in 1996...and since 2010 we own the original North American Westfalia skylight mold & cutout template, for earlier models with the skylight frame in the pop top but no skylight.

We are more than happy to assist folks with their skylight installation questions.

Please feel welcome to contact us!

Sun May 20, 2012 12:44 pm

This may help:
http://www.thesamba.com/vw/forum/viewtopic.php?t=422499&postdays=0&postorder=asc&start=0

Also Trevor (The Skylight Guy) is a big help.