INSUL-BRIGHT IN THE AIRSTREAM INTERSTATE, PART 2: GALLEY WINDOW

This post follows on Part 1 where I described the creation of a window covering for the Airstream Interstate's sliding door.  That was a different project because that covering basically hangs by Velcro tabs on the outside of the window frame.  This covering was made for what I call the "Airstream signature" window - the un-openable galley window that Airstream installed to maintain stylistic conformance with its historic product line.

If you Google "Airstream window", you'll get something like this collection of rounded-corner windows that tend to be wider than they are tall.  

That window has an inset frame with a wide rubber gasket on the inside.  The visually-cleanest way to make a thermal covering for that window is to inset it.  And the easiest way to inset it is to give it some stiffness so that it will stay in place largely without assistance.

I decided to try building on the existing Reflectix covering that I made for that window.  It already serves as a template.

If I could sandwich the Reflectix and the Insul-bright between an outer and inner cover, that would build on what I'd already done without having to re-invent the wheel.  I started by cutting a piece of Insul-bright to match the size and shape of the Reflectix I had cut a long time ago. 

The obvious question is, how does one sew Reflectix?  Generally I find that anything I can cram beneath the foot of my sewing machine, I can sew.

I started the construction much as in Part 1.  First the back portion went on, and the sandwich was sewn shut by applying a deeper seam. 

It's quite comical sewing Reflectix.  It goes pop-pop-pop-pop just like you are popping regular bubble wrap. 

Then I placed the workpiece and templated out the top metallic fabric cover.  This shows the wrong side of the metallic fabric.

It has been my intention all along to maintain a metallic fabric covering on the surface of these window coverings for conformance with Airstream's aluminum interior wall coverings, but I haven't yet found a metallic fabric that I like.  This is a different one which I am hoping will prove to be less fragile than the stock I used in Part 1.

Easing the corners was a bit of a pain.

You can see that I basically just top-stitched this fabric in place.  I like to have double rows of stitching on these window coverings coverings whether they hang or inset.  It seems to give a good finished look and some body to the outer edges.

There's the back side.  The stitching is a bit wavy because it is a challenge to feed that Reflectix sandwich through the sewing machine.

Money shots:

There it is in place, friction-fit.  I'll probably add a Velcro dot at the top just to be sure it stays well.  

Here's the part that perhaps appealed to me the most:

I've got a bigger burrito now.  This is the new one (right) stored next to one of the Reflectix old ones (left). 

It now looks like I have an actual professional automotive product on the wall instead of a cut sheet of Reflectix insulation.

Much better effect visually, I think.  A finished product which looks like it belongs there.  It makes the Reflectix look a bit trashy in comparison.  

So there's another prototype executed, and I'll report back on how it performs, insulation-wise.

Tryin' to make our ride cooler and cooler, in every sense of the word.