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Custom PVC Window Insert for Cat Flap — Fabrication & Install I need a two-piece removable window insert built from 18mm PVC foam board (e.g. Palight/Foamalux) to house a SureFlap Cat Flap Connect in a vertically sliding sash window. I'm renting so NOTHING can be permanently attached to the window frame — the insert must come out cleanly. WHAT YOU'LL DO: - Source materials: PVC board, stainless bolts (M5/M6), silicone, foam weatherstrip - Cut two panels: Piece A (755x271mm, solid) and Piece B (315x271mm, with cat flap cutout) - Cut a 165x171mm opening in Piece B for the cat flap (50mm border all sides) - Cut a 30mm shiplap overlap where the pieces join — Piece B's tab sits behind Piece A - Drill and bolt through the overlap joint (3-4 bolts) - Seal the joint with silicone, apply foam tape to edges, install in window I PROVIDE the SureFlap Cat Flap Connect unit. You source everything else. KEY DIMENSIONS: - Total insert: 1040mm W x 271mm H x 18mm thick - Visible opening: 1000mm (20mm each side sits in window grooves) - Cat flap cutout: 165 x 171mm - Shiplap overlap: 30mm HOW IT WORKS: The insert is too wide to fit in one piece, so it splits into two panels joined by a bolted shiplap overlap. Piece A angles into the left groove first, then Piece B angles into the right groove with its tab behind A. Slide together, bolt, seal. The window closes down on top to compress a foam strip. See attached diagrams for full details. IMPORTANT NOTES: 1. No permanent modification to the window — silicone is ONLY between the two panels, never on the frame 2. Precision matters — 1040mm total width must be accurate for the grooves. Please measure on-site to confirm 3. Cat flap cutout must be clean and square — the SureFlap frame clamps over it from both sides 4. Test fit before final bolting/sealing See attached diagrams for dimensions, cutout placement, cross-section, and install steps. Straightforward half-day job. Please quote materials + labour.

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