Hi friends.
I am completely rebuilding the top half of my 94 hilo and I have a side almost ready to go. I need to cut 2 new window openings and I want to do it right. I have nothing from the old side to give me a proper size opening other than a close location so I will have to use the windows for the proper size and I have read enough here to know they should be a snug fit for easy sealing. I have an idea that I need to use the window or inside frame for a template but I want to hear from others that have done this in case I may be overlooking something and experience is a good teacher.
Thanks to all and a Merry Christmas

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Charlie B
1994 245 TD

I haven't done it but I have re sealed all of mine. On some of mine the window openings were less than perfect all the way around. That said , if I was cutting them fresh I would focus on getting the bottom length level and leave maybe 1/8 -1/16 inch wiggle room between window and paneling as a general rule to make positioning and getting it in and easier. It's good sealing that will make it waterproof. And, yes, use inside frame dimension for. Template.

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2201 TL

2010 Nissan Titan king cab SE
4x4

Thanks for the reply. It is not going to be done for a while unless it warms up but getting it level is a priority and using the bottom seems logical but is something I hadn't thought about.

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Charlie B
1994 245 TD