1950 Liner "Weeble" - New old window made

Back to work on the airstream and made some progress. All 10 side windows are now in place.

When we got the airstream, one of the side windows was missing. I tried a few different tactics to make a new one but without a proper brake, I couldn't get a good 'u' channel. I took one of the original frames and hinge to a local metal company. Left it with them while they checked it out. Their fabricator basically said he wanted nothing to do with it. I then asked if they could just make the 'u' channel at 6' long and the hinge bends. They agreed to that using their brake.

A few weeks later I had 2 pieces at 6' to play with. I took some 3/8 steel sheet and cut two pieces template to fit inside each end of the window. I then mounted them to a 2x4 at the correct spacing and mounted the 2x4 to a sawhorse.



I made a block using a piece of wood and a 1/2" router bit. Using a propane torch, I was able to heat the aluminum in a few seconds and use the block to tap the aluminum around the corners. Then using a flat hammer, tap down the crimps. It worked really well.



Then I needed to make the crimps for the window arm which the vise and a few small pieces of metal worked well for. I also drilled the drain hole.



The hinges they made were decent but needed a lot of tapping and grinding to match the original. I had to keep running out to the camper to test fit until they finally worked. Once I had that done, I was able to drill the mounting holes and put together the window.

The top window is the original and the bottom is me reproduction.



This is the new windows mounted. The top window is the original and the bottom is me reproduction.



I was then able to polish the remaining 4 window frames and put the windows back together. Below are the completed windows on both sides. Only one set has seals and screen installed. Waiting until the shell swap to add the others.