We left off with a big new hole in the truck. Plastic works to cover it, but not exactly what we are going for.
So A gasket was ordered, its a rubber accordion shaped seal, its made to slip over a lip on either side. e left a lip around the hole in the box, that as easy, but we need to fill in the holes where the window was, and shape a lip around the back of the cab.
A little CAD (cardboard aided design) and we have templates for the window. I used the piece of the back wall cut out of the box, it has ribs in it take make for nice strong panels and was just big enough.
They were cut using a jig saw and skill saw, then trail fit many many times, a little grinder work each time and finally they fit in place nicely. Some sealant and a few bolts hold them in place.
Now we need to finish cutting the hole, if you remember I left the bottom not done. This took some serious doing, I went trough four carbide tipped blades trying to cut that Little bit off.
Once that is cut and the window panels are in place we can start to fit the gasket. The gasket is from Uni Grip, they makes lots of different ones. Its made for a nice straight flange, I have the back of a cab wall, not straight or the right size.
The seal was glued in place with polyurethane caulk, after hammering it onto the lip all the way around it seems to fit well! We have a connected box and truck!
Next up is more holes for doors and windows.