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Old 05-09-2012, 11:56 PM   #1
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Default Cutout for rear window Chevy Express/GMC Savana

I have to cut out a window hole in my rear door.
I don't have the glass and don't plan on getting it. I just need the factory sized swing-out window opening.
I want to make the right size cut though just in case I end up getting the factory sized swing-out window.
I bought the factory weatherstrip for the swing-out style Chevy Express / GMC Savana rear door glass for my model year. I think the rear doors are very similar from 1996 to 2006.



Problem is that I don't know where to cut.

The factory weatherstrip is flexible.



Also, I don't know how to position the weatherstrip.



It has two notches on the gasket side. Would they be positioned at the top or the bottom?

Back to the door cutting.
I'm guessing I'd cut within the outline provided by the inner metal panel.





I have an inner trim panel that I might use. The window opening dimension on the trim panel is approx 1/2" smaller all the way around than the inner metal panel of the door. I guess I could try fitting the weatherstrip on the trim panel window outline just to see if the weatherstrip is larger or smaller.



I'd really appreciate any help. Maybe a couple of photos of the weatherstrip/gasket from the inside of a van just to point me in the right direction.
Attached Images
File Type: jpg chev GMC rear doors.JPG (48.6 KB, 2062 views)
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File Type: jpg 021.JPG (126.5 KB, 2061 views)
File Type: jpg 019.JPG (312.8 KB, 2062 views)
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Old 05-10-2012, 12:46 AM   #2
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Default Re: Cutout for rear window Chevy Express/GMC Savana

Update.
I think I figured out the size of the cut. It looks to me like it is the same size as the inner metal panel on the door. The weatherstrip/gasket was much bigger than the interior trim panel but it fits the inner metal panel on the door pretty good.





I still need help re: positioning the notches in the gasket part of the weatherstrip molding. The notches are on the part that might touch the glass.
Here's a close-up:



Are they positioned at the top with the window hinges or are they positioned at the bottom for drainage maybe?
Attached Images
File Type: jpg 022.JPG (266.3 KB, 2057 views)
File Type: jpg 023.JPG (193.4 KB, 2058 views)
File Type: jpg 026.JPG (191.6 KB, 2058 views)
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Old 05-10-2012, 01:20 AM   #3
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Default Re: Cutout for rear window Chevy Express/GMC Savana

Would they be positioned middle bottom window edge where the flip clamp to open and close
the window rests, when the flip windows are opened? My rear windows open at the bottom edge
for ventilation.
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Old 05-10-2012, 08:28 PM   #4
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Default Re: Cutout for rear window Chevy Express/GMC Savana

I agree Mike, it must be the bottom........... makes sense - let air or moisture out as you close the window.
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Old 05-10-2012, 11:19 PM   #5
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Default Re: Cutout for rear window Chevy Express/GMC Savana

Looking at my rear doors, if there are 2 notches in the gasket about 13"-14" apart, they are
probably for the top edge where the hinges on the flip windows are situated.
I went and checked and the lower edge of the gasket that sits against and seals the closed
window, I saw no notch or gap in the gasket.
Some pics including one along the open lower window edge.
Pardon the quality, had to size them for upload, and the daylight was fading and at a bad angle.

We rarely open the rear windows because they aren't screened to keep the bugs out.
Attached Images
File Type: jpg 2002ChevExpressrearwindows 002smaller.JPG (59.6 KB, 1977 views)
File Type: jpg 2002ChevExpressrearwindows 003smaller.JPG (103.6 KB, 1977 views)
File Type: jpg 2002ChevExpressrearwindows 004smaller.JPG (133.0 KB, 1977 views)
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Old 05-11-2012, 12:18 AM   #6
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Default Re: Cutout for rear window Chevy Express/GMC Savana

Thanks so much Mike. I really appreciate that. The photos are helpful.

I didn't open the rear window on my RT much either. Sometimes the window latch has a screw in it to prevent you opening it when you have generator in your RT.
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Old 05-11-2012, 01:39 AM   #7
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Default Re: Cutout for rear window Chevy Express/GMC Savana

Hmmm, wonder if mine has one? I never noticed or looked at it that closely.
Anyway, if it helped, good stuff.
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