Thanks so much Daryl for all your help. I re-read the thread before I left on the trip, and your writeup was so thorough that I felt like I had actually done one before while I was doing it!
Got it on in camp yesterday, pretty much as planned. Since the glass and weatherstrip that were in there were only two years old, it only took about 30 seconds to pop them out. I was really glad I drug along the grinder and extension cord tho. I had to shave over a sixteenth off of each side, more like 3/32. I borrowed some power from my neighbor's Sportsmobile after spending several sweaty minutes trying to shave the thing down with coarse rasping files. D'oh.
Once I unpacked the butyl tape seal, I realized I probably should not have left it out in the back of the truck for five days! Double D'oh! I think it took me just as long to get it out of the plastic bag and carefully unwound as it took to grind the window down. Triple D'oh
Window went in like a dream.
Here's my first impression from the drive home. I had this vision of a tunnel of air from the flap under the windshield going past my head on the way out the rear. That didn't happen. The front vent and the rear window seemed to work at cross-purposes. Opening either side window caused a good volume of air to come IN the rear window, and apparently out whichever front window I opened. The only time I got air to exit behind me was when I used the foot vent. With the ambient temp of the floor being higher than the air outside, that experiment didn't last too long!
I brought along 1/4" strips of wood that I also happened to have laying around, but did not use them. The outside pulled down reasonably well, all things considered. One of the things I had not previously factored into my situation was that at some point in my rig's past a tree had fallen on the driver's rear corner of the cab. In 2001 I had cut the corner of the cab and cap open, straightened all the bent metal, welded it up and called it good. I could see that the stress from the impact had gone into the center section of the cab back as well, but never did anything about that. So when I fit the new window to the cab, it did not want to naturally compress into all four corners. I pushed it in a comfortable amount, put the ring in place and set all the screws. Some went all the way down, others were left sticking out about 1/8" when they snugged to the window frame. So my plan is to revisit the screw tension a few times over the summer while the butyl is still workable, and add washers behind the screws that don't want to finish the journey to the face of the inside ring so that they all end up having pressure on them.
Obligatory photos, complete with sweat stains.
