DIY Gullwing Window For Under $90 | Jeep XJ Winter Build Series Episode 5

Building an aluminum gullwing window to replace a busted out quarter window on my Jeep XJ. Learn how to make your own Gullwing window for just about any SUV.
Follow me on Instagram: / machinesincjake
Parts List
3/16" Aluminum:
Source from your local metal distributor
44lb Gas Strut:
www.amazon.com...
Waterproof Latches:
www.amazon.com...
Rubber Seal:
www.amazon.com...
Hinges:
www.amazon.com...

[@TravelinCatfish]

As an idiot that likes to watch KZbin then go HAM on projects. Now I’m gonna do the same! Nice video.

[@machinesinc]

Good luck!

[@Sco33a101]

Great work brother, just a tip for anyone also attempting this. Is when wanting to add a bend screw a length of timber to a bench with a 20mm gap between the bench and wood and slip sheet under and lift up. Works wonders

[@machinesinc]

Nice tip!

[@elev8j10]

Looks pretty good. Latches are cool. Don't know if you have this thing parked outside much but some security bolts on the hinges might not be a bad idea. I don't have room for my xj in the garage so I put security cameras on it and security bolts on the winch and anything that can be taken off easily. Thought I was being a little paranoid until my camera notified me at 2am and someone was checking the doors, looking inside, and crawled under it. I doubt he will be doing anything like that again but goes to show you never know.

[@machinesinc]

Absolutely, some security torx or latches with interior bolts would be more secure. Luckily I live in a very chill part of town and don’t have to worry about it. This Jeep only hangs out in my neighborhood and in the woods haha.

[@justinstjules8735]

3:35 i see you're garage helper also drinks on the job lol

[@machinesinc]

Gotta stay hydrated

[@MacsSpecialitiesMotorsports]

I need a gull window in my life! Thanks for the tips and tricks!

[@machinesinc]

You bet!

[@matchedbook1]

Very cool installation. We’ll need to see some wheeling adventures in the spring to check on those hinges. That left side window might need some work, too.

[@machinesinc]

I’ll put it through it’s paces!

[@equals-kl9hm]

Use acrylic, would work just as good and you dont lose visibility.

[@machinesinc]

Acrylic does not have the rigidity alone to create a tight and reliable seal around the perimeter.

[@SJ-EOR]

Awesome. I want those on my rigs. Another project.

[@machinesinc]

Go for it!

[@phl_knives]

Hey heads-up. Those Harbor Freight jack stands you have are recalled for unexpected collapse. They replace or refund for free. I noticed them in the background. I'm 99% sure that's the recalled ones. Otherwise, Great option for the XJ. I really like this idea. Clean and simple. I'm curious how those hinges are holding up. I would be worried they're a little small but not a super heavy project. Twist of the frame is my only worry on these gull wings. Well documented build and showing potential trouble spots is a big help. Working with different metals I've found pieces of pipe in a vise. 2 on one side and 1 where you're looking to achieve a curve works really well. You can make a jig to hold the pipes with 2x4s in a vise. Bend one side and then the other or without a vice use lag bolts, washers and ratchet/impact gun to slowly tighten the frame to bend the sheet around the single pipe. This is a common technique used in straightening knives in heat treating that works very well even with thinner steel. Thanks for the video!

[@machinesinc]

Thanks for the reminder, I probably should swap them out at some point. The whole gullwing system including the hinges has held up perfect. Use it regularly and zero issues so far.

[@kentuckywaves]

Great video! I’ve wanted to do plexiglass windows with something like that except four latches so I could take them off and give my dog some more fresh air. I didn’t realize how much it bends though. Anyway, thanks for the video!

[@machinesinc]

I originally wanted to do this project with polycarbonate. I ordered 1/4” and I agree, it was way too flimsy. So aluminum was the best option I could think of.

[@bryanhoward1587]

Why not make a frame with aluminum and then put the polycarbonate on it?

[@jeremyhanna3852]

The quick and dirty way to bend aluminum like you wanted is cover it in painters tape put 2 x4 on the ground cement works best lower tire pressure in the jeep to about 8 psi put the boards parallel to jeep get somebody to watch and hold aluminum with foot from sliding drive up on slowly use 4L if it needs more bend try adding more wood under edge if the needs to be sharper and more psi to tire

[@machinesinc]

Thats a great tip! I'll keep it in mind for the next project. Thanks

[@officialWWM]

I replaced both my side windows with panels a couple of years ago. Maybe it’s time to put some hinges on them 🤔

[@machinesinc]

Now we’re talkin!

[@JustSomeBigfoot]

Did you just silicone it down?

[@markwolo2524]

Great freaking idea , thanks for the video !

[@machinesinc]

Thanks for watching!

[@jerseybiker15]

This is rad brother

[@machinesinc]

Thanks!

[@jaredpursey3791]

Wow, love your automatic hammer😂😂

[@machinesinc]

😂

[@bp9749]

Ex specially. Lol. Great video man

[@machinesinc]

Never did pay attention in English class 😂

[@constructiontech1970]

Nice work! Looks great!

[@machinesinc]

Thank you! Cheers!

[@FinallyMe78]

Great job. Definitely been thinking of doing something similar.

[@machinesinc]

Go for it!

[@niceguysmotorsports]

I took a shot every time you said gas strut and blacked out halfway through

[@machinesinc]

So did I during building it

[@danhambrick6331]

Nice job Jake.👊👍👍

[@machinesinc]

Thanks!

[@jamesjr3802]

Love the video plus the bottle of tikilla on the workbench. Lmao

[@machinesinc]

That’s how the work in the garage gets done 😂

[@vintagestyle13]

Pre heat the aluminum with a torch along the line where you want the bend.

[@machinesinc]

I’ll try that next time!

[@underabigsky]

Awesome🤙

[@machinesinc]

Thanks!

[@daveoffroad7396]

Nice job..!,

[@machinesinc]

Thanks!

[@FC0BCA7E7A]

I’m confused as to how the latches actually lock the aluminum door in place from the inside. Can you elaborate on how they make a solid contact with the inside window pane?

[@machinesinc]

They are compression latches that push against the inside of the window pinch weld. The plastic trim and rubber seal is trimmed in this area for solid contact.

[@GundamWheat]

wicked

[@machinesinc]

👊

[@turdfurgisin5843]

Dude, your videos deserve 10x more views than they have at this point lol

[@machinesinc]

I wish!

[@FC0BCA7E7A]

@@machinesincyou left out quite a bit of info. Dimensions, measurements, taps, drill sizes, blades from the jigsaw saw, etc.

[@machinesinc]

@FC0BCA7E7A this channel is designed to be more of automotive entertainment than step by step how to. All dimensions and specifics will vary based off your vehicle and what components you decide to use.

[@bobmoto3528]

Why aren’t people using plexiglass? Strong, transparent, curve-able, tint-able, almost unbreakable.

[@machinesinc]

It’s not strong enough to hold a seal without an additional metal frame. I tried haha

[@stanb990]

Why are these type panels apparently not used on the 2door models I've see commercials available units that specifically state that they are not available for 2door And I would use hurricane hinge

[@machinesinc]

I think the 2 door just isn’t as popular for aftermarket support. But you could totally make one! I thought it would be cool if a 2 door one flipped down to become a table.

[@stanb990]

@@machinesinc exactly my thought, for a cook table I was wondering if it was a structural or safety issue But the supply and demand thing makes sense. I've almost decided that I want to replace my hardly used now F150 will an XJ

[@machinesinc]

You do have a point. The big glass on the 2 door may be somewhat structural since it is unibody. If you are not wheeling it super hard it probably wouldn’t be an issue. And XJ’s are great little cars to slap 31-33” tires on and go exploring. But really building one isn’t very cost effective and you have to do a good bit of additional work bracing all the unibody.

[@FC0BCA7E7A]

Oh, u removed the interior plastic paneling...I don’t want to do that. I don’t particularly like that bare metal look...can I just cut out a bit from the interior panel so they will lock into place? Also, you don’t show how you cut out the slots for the hinges...

[@machinesinc]

Yes I installed and trimmed the interior plastic about 1” in diameter around where the latch engages on the interior of the pinch weld. For the latches I drilled a hole in each corner and then connected them using a jigsaw.

[@jahcadman]

How did you cut your rear fender flares to match the cut quarter panel?

[@machinesinc]

Cutting plastic I like to use a jigsaw with a fine tooth blade. You can also use a die grinder with a cutoff wheel.

[@slywolf2025]

Your wife works on jeep like I do😅

[@machinesinc]

Same here 😂

[@lewiswolfe6053]

Where did you get the laches

[@machinesinc]

Link is in the video description!

[@livingadvantageous]

Where did you get the latches ??

[@machinesinc]

From Amazon, link is in the video description.