Since I had everything in CAD it was fairly easy to transfer the files for the cut outs to the software Vanglass uses for the router. The cut outs stay attached at a few stops for stability of the panel during cutting and it is also a good concept to leave everything in for the way home. I only needed to tape up the gaps.

The large panels needed about an hour and a half to be cut.


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The side panels had a rebate at the top and front for better and stronger connection to the roof and front panel. The outside edges are easy to cover with a small profile, so the van does not look like a cooling truck where they use wide angle to cover the joints of the composite panels. This is more labour intensive but the better and nicer technique. I had the panels made with gel coat only on one side for weight reasons. Inside is the raw fibreglass. We do not like white hospital walls inside the van so it would have been a total waste to but a gel coat layer on the inside and we saved a bit more weight this way.