↓ Advertise on Defender2 ↓

Home > Td5 > side window fitting
Post Reply  Down to end
Page 1 of 1
Print this entire topic · 
cherob1boats



Member Since: 25 Jun 2020
Location: derbyshire
Posts: 9

England 
side window fitting

Hi, new to this site and defender ownership, so i wonder if someone can help me with this. I have a rear window kit to install in my TD5 (90) . It is made by Britpart and looks like a good bit of kit. Can anyone tell me the exact distance i should allow from rear of hardtop to the edge of the frame of window or indeed any fitting measurements would be helpful. I want to put the windows exactly where they would be if fitted by land rover themselves..Thanks

Post #839736 25th Jun 2020 8:30pm
View user's profile Send private message View poster's gallery Reply with quote
gilarion



Member Since: 05 Dec 2013
Location: Wales and Manchester
Posts: 4866

Wales 2007 Defender 90 Other CSW Trident Green

use a template made from cardboard for marking out. The easiest way is to
draw closely around the window frame, then measure the rebate in the frame
and mark a line the rebate depth + 1mm inside the outline for the cut line.
You want a hole in the body just a gnat's whisker smaller than the window.
Use a felt pen for marking the bodywork.
A good jigsaw with a fine blade will cut the metal easily - just watch for
the stiffeners inside. Drill a 10mm hole INSIDE the line to start the blade
off. Go slow and finish off with a fine file if necessary.
Mask the outside of the panel well before cutting - the jigsaw WILL
mark the paint if you don't.


For the exact Land Rover fitment, I would suggest you source a Defender with factory fitted windows and measure the distance from the gutter and the bottom of the top panel then mark these on yours and then fix the tempalte to these measuremnts.

Use dum dum to get a good seal - it's awkward to work with but does the job. For those who like Welsh Mountains and narrow boats have a look at my videos and photos at..

http://www.youtube.com/user/conwy1

Post #839869 26th Jun 2020 2:23pm
View user's profile Send private message View poster's gallery Reply with quote
cherob1boats



Member Since: 25 Jun 2020
Location: derbyshire
Posts: 9

England 

Thanks for that. do the riveted stiffeners need to be left in place or can they be permanently removed?

Post #839995 27th Jun 2020 8:41am
View user's profile Send private message View poster's gallery Reply with quote
mattc



Member Since: 10 Apr 2019
Location: Cheshire
Posts: 43

United Kingdom 2005 Defender 90 2.5 TD HT Java Black

This might be handy.

Post #840003 27th Jun 2020 9:56am
View user's profile Send private message View poster's gallery Reply with quote
cherob1boats



Member Since: 25 Jun 2020
Location: derbyshire
Posts: 9

England 

last questions on these windows and thank you for the replys. Does fitting side windows devalue the deefender, do I need to inform dvla and does it make insurance cheaper or more expensive? Ive marked out and am ready to cut but think id like other peoples input before firing up the grinder cos once i start its pretty final! regards Bob

Post #840086 27th Jun 2020 6:48pm
View user's profile Send private message View poster's gallery Reply with quote
tolley



Member Since: 07 Nov 2011
Location: gloucester
Posts: 1069

United Kingdom 2006 Defender 90 Td5 CSW Oslo Blue

I have a paper template when I did mine if you want it . Thumbs Up

Post #840087 27th Jun 2020 6:48pm
View user's profile Send private message View poster's gallery Reply with quote
cherob1boats



Member Since: 25 Jun 2020
Location: derbyshire
Posts: 9

England 

Hi all, firstly thank you for the replies to my fitting windows enquries. If anyone is interested, i rang dvla this morning to see if any changes needed to be made to v5 or taxation class with fitting side windows and the said not. I told the insurance company of the modification when i took out the insurance and dont think that cost extra either. So the grinder came out and one window is in. Really pleased i did it. Its now a nice light area. Big difference. Doing other side tomorrow

Post #840545 29th Jun 2020 8:47pm
View user's profile Send private message View poster's gallery Reply with quote
mk1collector



Member Since: 17 Sep 2009
Location: huddersfield
Posts: 6502

England 2004 Defender 110 Td5 CSW Bonatti Grey

Get some pics up Thumbs Up Ray
My build thread
http://www.defender2.net/forum/topic17615.html

Post #840566 29th Jun 2020 10:30pm
View user's profile Send private message View poster's gallery Reply with quote
cherob1boats



Member Since: 25 Jun 2020
Location: derbyshire
Posts: 9

England 
side window fitting

Hi all. Hopefully a couple of pics of landy are on here. Just a quick word on how I fitted the windows that may or may not assist anyone attempting it. Firstly I took all my measurements from the back and bottom of the panel to be cut. I did notice about 3mm run out in panel over length so check this first. Also the window frames had a couple of mm difference from each other in size as well. I used a biro to mark out the cut line on the masking tape as pencil seems to disapear in front of the grinder blade. I left the stiffener in place until i had cut the entire panel out as the panel is bonded to it. The stiffener holds it in place nicely when the cut is finished instead of the cut panel falling down the side of your nice paintwork. The panel peels off quite easily giving much better access to the rivets for drilling, if youve got side facing seats. I used one half of the box that the windows came in to cover the cut on the inside. Believe me, this saves loads of mess and swarf going all over the inside. I made the cut using a jigsaw and grinder with 1mm blade. No need to drill a 10mm hole to give jigsaw a start on the corners, just cut a slot on your cut line in front of the corner in the direction you want jigsaw to travel. Make sure you mask the corners sufficiently to cover the foot of jigsaw when cutting the corners. I was very conservative in the actual cutting and each window took about 4hrs to fit. On this job you can always take away but not add so i had quite a bit of filing and fitting up to do after the easy bit. I fixed in position with 4mmx6mm rivets and soudall fix all crystal super clear. Mask around the outside of the window before offering up with sealant to catch the excess that squidges out. Thanks for your responses guys. Gave me the confidence to make first cut![/b]

Post #841944 5th Jul 2020 5:40pm
View user's profile Send private message View poster's gallery Reply with quote
mk1collector



Member Since: 17 Sep 2009
Location: huddersfield
Posts: 6502

England 2004 Defender 110 Td5 CSW Bonatti Grey

Looks great Thumbs Up Ray
My build thread
http://www.defender2.net/forum/topic17615.html

Post #841957 5th Jul 2020 6:56pm
View user's profile Send private message View poster's gallery Post Reply
Post Reply  Back to top
Page 1 of 1
All times are GMT + 1 Hour

Jump to  
Previous Topic | Next Topic >
Posting Rules
You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum



Site Copyright © 2006-2020 Futuranet Ltd & Martin Lewis