Friday May 10                                                   Sunny & hot                                                     Castlegar, BC

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Well, there was no putting off the inevitable - today was the day Ali would get his new window. The weather was fine so no more excuses, Mason, just do it.

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I carefully measured and drew the "cut" lines on the interior of the door. I figured once that was done, cutting the outside of the door (the aluminum skin) would be easy.

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Cutting the interior luan (thin) plywood exposed the white styrofoam insulation in the door. You know, the kind of white styrofoam that goes EVERYWHERE and sticks to EVERYTHING!!  

Then I tackled the aluminum skin. My borrowed jigsaw with a new blade made one heck of a racket! When I finished cutting a large enough hole, I completed the job with my tin snips.

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I didn't think (duh!) to test fit the window before I completed cutting the hole in the aluminum skin. So while the hole on the interior side is square to the door, the corresponding hole on the outside is not. It's off by about 1/8-1/4". Most people won't notice this, but it'll bug the hell out of me for a while.