We were in a rush to wrap up some projects so we could hit the road on our first trip. One of those projects was reflectix window covers with some basic insulation. With some reflectix, magnets and duct tape we were able to make some tight-fitting and surprisingly simple window covers. Eventually we will upgrade these basic covers to include better thermal insulation and some nylon fabric. Here is how we made ours for less than $100 bucks.

Material, Tools, Cost & Labor

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[ebs_toggle active=”active” ocicon=”true” title=”Parts & Material” icon=”fa-gears” icontype=”fa” iconcolor=”#ffffff”]• Reflectix – http://amzn.to/2CdyHKs
• Magnets – http://amzn.to/2CeL494
• Duct Tape – http://amzn.to/2Cdy57C
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[ebs_toggle active=”active” ocicon=”true” title=”Tools” icon=”fa-wrench” icontype=”fa” iconcolor=”#ffffff”]• Scissors
• Box Cutter / Blade
• Tape Measure
• Black Marker
• Large ruler or T-square

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[ebs_toggle active=”active” ocicon=”true” title=”Cost & Labor” icon=”fa-clock-o” icontype=”fa” iconcolor=”#ffffff”]Total Project Cost: $90
Installation Time: 2 Hours[/ebs_toggle]
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Process

Step 1: Making Templates

This is the most time-consuming part of the project, as you will want to take your time to be as accurate as possible. For this, you’ll need some large pieces of cardboard. You’ll end up with several unique cardboard templates depending on the van configuration you have. We have a single sliding door window and rear windows. This produced 3.5 cardboard templates (I’ll explain the .5 template in a bit).

Start with a piece of cardboard that is slightly bigger than the window you are working on. Pick an edge of the window to begin marking the cardboard against. I prefer the longest straight edge of the window to save time and cutting. Start marking small sections with a marker and trimming as you go. As you work your way around the window, it will become easier to fit the template to the window. On the driver and passenger seat windows you can roll the window down to mark the majority of the template from the outside.

Though this can be done by one person, larger window templates (windshield) will be easier with a second set of hands. It’s important that you get the cardboard as precise as you can, even if you have to tape a piece of cardboard back on to correct a minor imperfection. Fit  your template in the beveled window sections, about an inch away from the glass, to enhance the effects of the reflectix. If you have the cover pressed directly up against the glass,  some of the radiant insulation properties of the reflectix will be diluted. Once you add the magnetic tabs it will be held in place away from the glass.

Once the fit is good you’ll want to indicate where to place the magnetic tabs to hold the cover.  Place them in locations that are evenly spaced out, and on a flat metal area of the body. Avoid obstructing the weather seal. A particularly bad spot seems to be the upper corners of the front door windows. One tip is to use the seal created when the front doors close to secure your covers.

On the rear windows of the transit, the passenger side window is not as wide as the driver side. You can make the template for driver side and transfer it to the reflectix. Then cut it in half. Place these two halves in the passenger window, and tape them together once they fit perfectly (they will overlap, that is okay). The shape and corners are the same between the two windows. Since this is not a brand new cardboard template, it’s the “.5 template” mentioned above.

Step 2: Cut Out Reflectix

At this point trace your template onto the reflectix using a black sharpie marker. If you made a good template, this is the easiest part of the project. You’ll want to use a good pair of scissors to get clean cuts. Try to cut your templates from the reflectix in the most effective way to minimize the waste.

Step 3: Add Magnetic Tabs

With the reflectix cut out, you are now ready to add the magnetic tabs to hold your covers in place. This consists of cutting a 5″ piece of Duct Tape and placing a magnetic (or two depending on your magnets strength) into the middle of your tape.

Then you evenly apply the tape to one side, folding the tape onto the magnets and then to the opposite side, this will create a tab on the reflectix with the magnets sandwiched in the middle. You’ll want to place the tape so you only have about a 1″ tab with the magnets on the outer edge.

This is an incredibly simple process but is highly effective. Take your time and make sure the tape is being placed inline with itself so when you fold the tape you don’t have any adhesive exposed for that super clean look.  After testing the covers you can come back and add more tabs as necessary if your covers are not staying in place.

Our Experience

Build Process

Making these covers is not complicated but takes a little patience. This has been one of the easiest van projects yet.

Performance

These did a great job creating privacy and blocking some cold from the windows on our fairly frigid first trip in the van. However, with the temperatures dipping down to 18 degrees, they didn’t blow our minds with performance. These were super easy to slap on the windows at camp. Time will tell, but these seem to be sturdy enough that they will hold up for some time if treated with minimal care. The magnets appear small but are very powerful and easily hold the covers in place, blocking almost all the light from the windows.

In Retrospect

Currently, I have no regrets in making these. Once we add on some insulation and nylon material I’ll report back.

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