List Your Mods:

I got the window from Hehr International in Indiana. It is from their 5900 series. They have any

size you want and you can get them with or without sliders, tinted etc. I chose a fixed window.

If you look at the picture of the R-Pod framework below you can see the bottom rib that I used (Black Arrow). I cut through the middle rib (Blue Arrow) and added a rib below the Red Arrow.

You could have a window as high as the red arrow.

Once the window arrived (took 3-4 weeks) I traced the outline onto cardboard to make a template for the frame. I set the pencil so that the outline was about 1/8" bigger all around. To compensate for the curvature of the Pod I made the frame 2 1/4" high. This way the window will be sealed against a flat surface inside and out. I then made a gluing jig for the frame 3/4" smaller than the template as I was using 3/4" pine for the frame.

I traced the four rounded corners onto 2X4's and cut them with a bandsaw. I then cut the 1X3" Pine (trimmed to 2 1/4" wide) pieces to fit between the round corners. I used a good quality exterior wood glue and clamped the whole thing against the jig. I then sanded the whole thing smooth with the following result.

The plywood shims were added because the glass side of the window has a smaller ID than the inside frame and I didn't want it to shift while I installed the window. I then painted it with black Rust-Oleum to match the window frame.

I cut a hole on the inside of the POD at about the center point of the window location so that i could accurately find the lower rib. I then cut along the bottom rib as my starting point. Next hold the finished frame against the wall with the bottom lined up with the lower rib and trace around the frame. A jig saw with a short blade was then used to cut out the rest of the wall. I used a short blade so it wouldn't penetrate the outer wall.

Next I used a pencil to transfer the inner cut to the outside wall  and cut that out with a longer blade.

Now I glued in a 36" long rib between the inner and outer wall at the top of the hole to give stability to the walls and to have a strong anchor point for the top of the frame. I used high strength construction adhesive.

Next I inserted the frame and screwed it to the bottom and top ribs as well as the ends of the middle (blue arrow) rib that was cut with the hole.

I then applied a liberal amount of silicone caulk to the outside and ran a nice bead on the inside to seal the whole thing up. It was then a simple matter to install the window according to the manufacturers directions.

Can you recommend a good cover?