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Aluminium side windows?


Nigelw
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Might need to remove the rear side windows in the Disco 1 to comply with Dutch tax regs regards commercial vehicles.

Been looking for some sort of composite blanking kit but can't find anything for my 3 door so would still need to find a solution for the two middle windows.

Has anyone done anything with either flat ally panelling or chequer plate to good effect on their side windows?

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Take a look around for something called Dibond - it's typically 2mm thick and is a composite panel of plastic core sanwiched between two layers of aluminuim facing.

You should be able to create a cardboard template, then use this to mark and cut the Dibond, then mastic the resulting panel into place with RTV sealant.

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  • 3 weeks later...

Easy fix, if you're any good with fibreglass:

Remove the rear windows, clean a sheet of glass bigger than the window by at least 50mm all round and lay it on a flat surface. Rub car wax polish onto the glass and then paint it with F/G resin , lay on a sheet of F/G cloth, as heavy a weight as you can obtain and paint more resin on - at this stage add to the resin some enamel paint as close to the body colour as possible to tint the cloth - make sure that the cloth is at least 25mm bigger than the glass allow 24 - 36 hours for it to set.

Once it has set place a window that you have removed onto the fiberglass and draw out the final shape, remember it has to be at least 25mm bigger all round as you want it to be a good fit into the rear window recess, trim it to this rough shape.

Put it up to the opening and trim it to the exact size of the rebate, run a bead of sikaflex around the opening press on the F/G (nice smooth side to the outside) panel and fix with wide head blind rivets.

If you can obtain some kevlar cloth sheet leave it as is, (no colouring) it will look very impressive.

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My Discovery commercial was a four door with side windows, they were just a very very dark tint.

You couldn't see anything through them although you could observe sun spots through them, so there was some light transmission.

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Its interesting to see the differences in regs throughout EU - here in Norway we take a brand new top of the range LandCruiser, take the back seats out, fit a dog guard and put green plates on it.

At the end of three years we stick it all back to normal and sell it as a car. As its a top of the range car it commands a very high price.

It *almost* costs you nothing for three years motoring.

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Its interesting to see the differences in regs throughout EU - here in Norway we take a brand new top of the range LandCruiser, take the back seats out, fit a dog guard and put green plates on it.

At the end of three years we stick it all back to normal and sell it as a car. As its a top of the range car it commands a very high price.

It *almost* costs you nothing for three years motoring.

My Irish registered Trooper had the seat belt mountings welded over and a steel boxed over rear footwell, at the time there it was once converted it couldn't be easily put back, at my last work place I stripped the rear seats out and put the wood floor in every year for the MOT, then swapped it back again, the heavy tints disguised your rear passengers, rarely got stopped as it was very clean and tidy and driven by a girl, the great art of tax avoidance!

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