Fitting Side Windows to a Defender 90.

Brom Hi,

it is really straightforward to fit them. You will just need to make a good template using thick carton paper. Using this template you will mark the openings for the windows on both sides. Best way to do the template is to copy it from another Defender with factory fitted windows. Be careful though this template will only work OK if you fit genuine LR sliding windows.

You can also use pattern ones but make sure they are decent quality so that they will not let water in (as if the genuine one do that.....) and are similarly sized. Paddocks is selling aftermarket ones supposedly of the same size as the factory ones I think.

Buy the best panel cutter you can in order to do the job properly and remember to mask everything properly before you start cutting bits away.

Take care Pantelis

On or around Mon, 6 Dec 2004 07:43:45 +0200, "Pantelis Giamarellos" enlightened us thusly:

and remember the old Carpenter's adage: measure twice, cut once, not the other way around!

one of the mags did this mod using aftermarket windows a while back, and didn't report any problems as I recall. Critical to get the hole right, though.

So Austin Shackles was, like

Absolutely.

Got mine from BLRS, I think. Easy to fit (half a day for the pair) and never leaked or rattled, a bit over £100. I was well pleased. To add to what has been said: I used a template made from cardboard for marking out. Easiest way is to draw closely round 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 sole WILL mark the paint if you don't. I didn't, and it did. Use dum dum to get a good seal - it's awkward to work with but does the job.

Good luck - it's a modification well worth doing. Exit from side roads with confidence!