Tom’s Expedition Vehicle Build:
Part of the reason I came to Arizona in May was to see Tom’s truck. While I’m here mooching electricity off of Tom’s family I though I would chip in on the Expedition Vehicle Build. This post is mostly about cutting in the windows. If you want to follow the whole build you can see it at https://www.expeditionportal.com/forum/threads/2009-chevy-medium-duty-4×4-kodiak-ambulance-conversion.191535/

The door window stays. The other window will be removed.

The house-part of the truck had only one window on the curb-side to start with and it was in the wrong place for the interior design. Tom planned the windows so a person standing inside can see out without needing to crouch down (A feature most coaches lack in every way). That meant the windows needed to be placed high on the walls. First Tom cut in the rear street-side window, then we cut in the forward street-side window. We needed the cut-out from the forward street-side window to plug the hole left behind when we took out the factory curb-side window which was too low and in the wrong place.

Removed the window and plugged the hole with a cut-out from the other side

Once we plugged the factory window opening with the cut-out we could cut in the new window openings for both curb-side windows. After the new window openings were cut in we added structural supports on the inside to carry the roof load to the floor and mitigate any diagonal-load issues.

Cut two new openings

The end result is a very spacious and airy living space with ample cross ventilation. The windows are at eye-level when standing inside and also at eye-level when sitting on the raised dinning area. Given the height of the truck and the raised windows it’s also very difficult for someone outside to look inside without standing on a 6-foot ladder.

Two new windows in the correct place

Tom and his dad cut in the window on this side

Tom admiring his handy-work