Buidling a new roof window

September 18, 2023

The existing roof window had gotten old and a bit worn out. I wasn’t completely satisfied with its design, because I couldn’t simply open it for ventilation. Instead, I had to force it into the guide rail which increasingly wore down the frame over time. It also had only a thin plexiglass pane, offering poor insulation and causing a large cold bridge where condensation formed in winter. What bothered me most was the lack of any mechanism to secure the window during driving or during strong storms. The improvised tension strap I used to fasten the window to the bed was annoying and didn’t look good either.

Tension strap to fasten the roof window to the bed

It was time to build a new, improved version: double-glazed, with a proper opening mechanism and a locking system.

First, I cut the side pieces of the base frame to size and marked the curve of the roof.

Measuring the base for the window frame

Next, I built all the parts, sanded them smooth, and treated them with oil.

Cut, sanded, and oiled: all the individual parts of the entire window construction

Inside the completed frame, I fitted a plexiglass pane, then added a thicker pane that extended well beyond the frame to offer structural protection against the weather.

Assembled frame with double glazing made of Plexiglas

With a slight clearance on all sides, the construction fit perfectly into the roof hatch.

Window placed into the guide rail in the roof

Inside, the window rested on the opening and securing mechanism.

View from inside of the window in the roof hatch

Two toggle latches on both sides allowed the window to be firmly secured, preventing it from opening during travel or in heavy winds.

Toggle latch for securing the window

To ventilate, the window could be lifted and set on the opening mechanism. The generous overhang of the outer plexiglass pane allowed for ventilation even in light rain, keeping water out of the sleeping area.

Opened window

After being bothered by mosquitoes, I added fly and mosquito screens to the openings.

Window with installed mosquito and fly screen

From then on, I could comfortably enjoy fresh air while lying in bed.