Easy DIY Gull Wing Windows! Ultimate Land Rover Discovery Build Episode 6

[@matthewbrown5334]

I own a Disco 2 2004 in the US and it's my "family suburban," and I'm in the process of purchasing a Disco 2 TD5 in Africa for our Africa-side "family vehicle." Really love this gull wing idea and that it was done on a Disco!

[@elitehuntclub]

1-ton axles on the stock engine... oh boy... I had a 2000 Disco 2 on 37s (Pitbull Rockers) and used Great Basin Rover parts to beef up the axle shafts and diffs and with a TrueTrac rear was able to have all the fun a full body rig could have in Moab! With the 37s with re-geared diffs, the engine was still not happy bout the situation. I ultimately downsized to 35s and it was PERFECT! Just my opinion when going with 37s. Also, the only suspension modification that I needed to do was get rid of the watts link in the rear and go to a traditional panhard setup. Worked GREAT! Just some info from experience... I miss my disco 2 almost every day... glad you're showing the rover crowd some love!

[@grey3977]

"It worked great until it didn't " lol story of my life. Any project I attempt I have to double the expected time and cost to account for my mistakes. Thanks for making me feel normal. 😀

[@jonatday]

Great video and inspiration for many people to have a go at doing this, a little fire service tip is to cover the whole pane of glass you are working in with gorilla/duct tape so that if it shatters 99% of the shards get held together in a big slab of broken glass, it's better for the casualty 😉 Thanks for taking the time to make such a slick video Hello from London 😊

[@wyattoneable]

Me too. My favorite times are when I can be creative in the shop. You did a real nice job on this project.

[@DirtLifestyle]

Thanks!

[@4schitzangiggles]

I use SikaFast 3121 to bond and seal the rivnuts. It seals out moisture preventing corrosion and also keeps it from spinning if you end up getting a less than perfect crush on the rivnuts. Also if you look at marine/rv applications for how they are sealing windows and hatches it can save you having to reinvent the wheel. Shimming out the hinges (with washers or a shim between the hing and vehicle body) will also allow you to use the thicker side bulb seals. I've done some with 1/4" and 5/16" Lexan/polycarbonate and for curves like your Disco has you can put it in an oven to heat it up and lay it on top of the glass to get a near perfect bend/curve to match the shape of the glass/body. Keep up the great work!

[@codybrady6637]

Do you got any tips for forming lexan without an oven? My side windows are 4 feet long

[@Rick_Sanchez_C137_]

Cody Brady Temperature adjustable heat gun... Lay it over top of original window, clamp in place, start moving heat gun around aiming at it and then let it cool.

[@nickopedia5669]

That oven Idea is ingenious. And you can put a tint film on it to protect from scratches/yellowing. (and replace the tint every few years when it turns ugly)

[@koitorob]

If you don't remove the burs from the inside of the hole you may get a looser than required crimp on the rivnut. Just buy a deburring tool. Run it around the inside edge of the hole and then install your rivnut. Smearing some sealant around the rivnt is a good idea to keep water out, as would painting the raw hole edge too.

[@FlaccidRooster]

I love how detailed you are. This channel is just pure gold.

[@donhappel9928]

Nice work - I don't often see these on Discos but several of my Defender friends are running them. Often they build out an inner compartment with shelves/whatever to keep one 'window' as a dedicated work area. One is set up a quick-stop galley where he has a fold down table similar to what you built on the rear door and pressure water plumbed in. The interior compartment then holds a small stove. Any time he needs to fix a quick hot meal (he often takes his young son on the trail) he can just pop the hatch and have everything he needs right there including the work surface without having to actually open the main compartment of the truck. Of course he tends to re-work his setup often enough he may have already changed it to something else.

[@prancstaman]

I was going to just cover up my windows into a wall till I seen his. Making a tool truck and would be perfect for tool boxes on the side of my Waggy. Saved to my favorites, LOL.

[@DirtLifestyle]

Sounds like a bad ass project 🤘

[@craigmaurer8484]

Little tip on mounting gas shocks, if in the closed position the door (or moving side) mount sticks in further than the frame side (or fixed side) the shock breaks over center and helps hold the door or window closed. Not a critique, just passing along some of my experiences. Looking VERY forward to the 1 ton videos! Keep up the great work Nate!

[@DirtLifestyle]

Good stuff man, I will keep this in mind 🤘

[@stanciotola6632]

Nate just seems like a super nice, relaxed ridiculously talented dude. Love these videos and watching him work.

[@prankster671]

These kinds of windows make so much sense.

[@samsoncarr9950]

One of the reasons I enjoy following your channel, all the diy content.

[@TheAmericanUhate]

Being an overlander build, would have been cool to make them both fold down into tables instead of up. Extra table space is always great when cooking on a trail somewhere.

[@worcesterrenewables6946]

That is exactly what I am doing. Also our lanes are particularly narrow in the UK and occasionally we're wedged and can't open a door, so window exit :) By folding down, I can reach recovery gear etc though the side rather than having to walk round to the rear !

[@BuzzzdLightyear]

Yeah but it would be harder to reach into the back of the truck which is what I think he's going for. If it folds down, you're like 2 feet further away from whatever you're trying to get at.

[@TheAmericanUhate]

@@BuzzzdLightyear Isn't that why the back of the vehicle opens up? Could be boxed in on the window opening and a shelf that holds different things, still in reach

[@BuzzzdLightyear]

@@TheAmericanUhate yeah but I'm guessing trying to build a storage system that can have multiple access points instead of opening the back and having to move stuff or pull out trays/drawers to get to what he needs. I do like your idea of having the windows boxed in with storage though.

[@rollinamerica]

Long as you get a good seal so water doesn't leak in that might not be bad.

[@guitar14]

Same goes for the 80 Series Land Cruiser. Gullwing windows are 700 a side. Great video.

[@DirtLifestyle]

Very pricey indeed 👍

[@mazevx2451]

@@DirtLifestyle jeep jku is about the same, 850 or more for the side window boxes, I get it they build in the US and all but that's a lot of money for a storage box... Your gullwing solution is really great!

[@phillipdoubleu5474]

I would suggest to invert the gas strut. The oil will settle to the bottom keeping the seal lubricated.

[@DirtLifestyle]

Good suggestion 👍

[@Username76234]

I was hopeing someone was going to say they are upside down 🙊

[@questioneverything1123]

I love your work Nate, it always looks "so factory" Your resilience and abilities to improvise is a strong testimony to your vast DIY skills. KUDOS!

[@DirtLifestyle]

Thanks man!

[@FarmerSarducci]

You should just lay those aluminum panels on a welding tanks to put a little pressure to get the curve you need. It won’t take much.

[@therealgaragegirls]

I was thinking the same thing.

[@VGrillone]

Excellent! Thanks! I have an ‘04 D2. She’s my baby! :)

[@pnwxplored]

I just deleted my 95 tacoma rear extended cab seats for custom overlanding storage! video coming out soon! My next project is to pull my cab windows and add gull wing windows. Learned a lot from your build - was just what I was looking for, so thanks a ton mate!

[@jonstarritt848]

Those look great! To test the seal and water tightness of the assembly you could spray it down with a water hose. That way if there are any leaks or problem areas you can take care of it in the shop before you find it leaking on your gear on a trip.

[@macmurfy2jka]

These will be going in the driver’s side on my Jeep eventually. I never use that window to see out of anyway!

[@jaegarfiftyeight8048]

Good honest video. Did this modification on a D1 last year. As well as using a smaller diameter side bulb seal, if you had mounted the hinge plates which are riv-nutted to the bodywork on small spacer blocks to locate the top of the new lid slightly out from the window aperture, you would achieve a more even closing of the door onto the seal. If you really want a spot-on seal all the way around, using a twist lock in the centre with lateral locking bars that locate behind each bottom corner of the lid is the way to go. 👍🏻

[@stuartmorton3083]

I got my wife an 04 disco as her adventure rig. Been going through it fix/upgrading the problems. Pulled the headliner out and took off the fabric and put a spray on bedliner so no more sagging headliner again. Pulled sunroofs out cleaned and resealed and rebuilt the motor so the front opens again. Have new 180 degree thermostat to keep it running cooler and not overheat. Can't wait to see how you tackle the diesel swap I plan to do one in it as well and also my 06 Tacoma. Great work and might see you around im just a little bit up north of Seattle.

[@michaelhalstead64]

One of the best channels on KZbin. Great work.

[@jeepindave5464]

My day is always brighter with dana 60s

[@comingtofull-ageinchrist6736]

an English Wheel would have came in very handy to put that little bit of curve in the aluminum panel. "Make It Kustom" and "Lazze Metal Shaping" both show some excellent how to on the English Wheel and the bead roller. No more than that is curving, it wouldn't take much work at all to get it to fit right. Great video, Nate!

[@tontonkaldoche3481]

Wonderfull work but the word easy must be forgotten .perfect style for handyman.

[@gregnorvell9730]

Cant wait to get my kitchen remodel done so I can get back out to the shop! Wanna build a set for my Cherokee.

[@smithyoftherust]

You know, channels like yours give me confidence that the big projects I want to do are actually doable. I have an 84 Chevy S10 that I eventually want to convert to solid axle dana 44s, among other upgrades. Going to require completely redoing the suspension, getting rid of the independent front and the torsion bars.

[@Raceydog]

Add some 1/4” spacers behind the hinges where they mount to the body. It might move it out enough to use a bulb style gasket. And try bending the aluminum slightly to match the shape of the window for a better seal all around.

[@csabin312]

Once again you make things look so easy

[@DirtLifestyle]

Thanks!

[@hotshtsr20]

One thing not discussed but you did do on this install: the seam where the two ends meet should be on the bottom edge.

[@xerointell]

Yet another use for rivnuts. Where would we be without the ability to thread sheet metal? 😂

[@malcolmyoung7866]

That's just nuts...

[@TheBibleExplorer]

That's going to be an awesome ride when it's all said and done. Hope you and your family have fun on your trip and can't wait to see what you got in mind for the storage area.... And always.... Keep the tires aimed at the ground & your eyes toward the Lord... There's great wheel'n ahead brother 😁👍

[@watchchannel8201]

I a discovery 2 owner and I love these vids. Don’t stop making this content bro.

[@scottc0510]

I've been thinking about something similar for my square body Suburban "bug-out vehicle" build. I initially considered just removing both the big side windows and just filling in where the window was with sheet metal, but I can definitely see a benefit with having something that would open up like your metal window replacement.... I've also planned to build a pretty large'slide-out storage organizer that bolts to the floor in the rear. As I have it planned now, the organizer would pretty much fill the rear cargo area and be able to slide out through the open rear doors of the truck. Still trying to work on the design now. Having side access like you've done here would allow me to mount some things to the outside of the organizer and retrieve them easier, when needed.... Great job on this build so far, Nate! :-)

[@DirtLifestyle]

Cool project! My buddy david has a barn door suburban built similar to how you are describing. I highly recomend checking out his build at willomet motor and fab 👍

[@chingon_grandpa]

Damn, I do not have that talent.. breaking the window is about all I'll get to.... definitely want these for my Rover Classic. Great job m

[@WeekendWrenchTurner]

Nice!! I've got a love/hate feeling with this video. Love it, because it's a brilliant idea and well executed. Hate it, because now I want one on my 4Runner😕

[@DirtLifestyle]

Lol

[@TheGreenNewSteal2025]

You called it. I’ve got a very nervous Landcruiser in the driveway that knows full well how mediocre of a fabricator I am lol.

[@trailrunnah8886]

Was just thinking the same thing! At least we have the roll down rear glass, my dog loves that.

[@ladydi4runner]

Green around the Gills, are we ?!?!😮 Why, yes , yes we are. 😱😳🙄🤣 Yes, am now looking at my 4Runner back windows quite suspiciously! 😏 They are quite anxious...😂🤣🙃

[@Rick_Sanchez_C137_]

Weekend Wrench Turner Hahaha, NO, now you want TWO on your four runner....

[@danc.452]

That actually came together really well.

[@jtdehaanjr]

Love it Nate! Either this or a set of rotopax holders is on the list for the XJ. Looking forward to the future of this project.

[@damiangillett6443]

An educational, well presented video. Thank you for sharing this.

[@crayfishroll]

Super stoked for this build too !!! I have a tj and a 5.9 zj and always wanted this body style disco. Now I just have to convince my gf to let me buy one .......

[@3WK-ADV]

This was literally my first car, 2003 Disco 2 in White. Seeing this makes me want one again.

[@t.h.o.r.]

Dude!- all that lovely work and you mounted the gas struts upside down! the body should be at the top to keep the seals lubricated. Now you get out there and swap them over right now!

[@philkrenelka4324]

Just a thought - If you added a shim or some washers to the back of the upper hinge I think you might have been able to use the first seal you tried. Great channel! Thanks for your work.

[@Rick_Sanchez_C137_]

Phil Krenelka I was thinking the same...

[@alvitiello9134]

I love the idea of the Goldwing windows I would use that on my cap on my pickup truck instead of the sliding glass windows great idea thanks 👍

[@mattvivona]

Stoked for the 1 ton axle swap!

[@sanatandharma4435]

I want to do something like this to my old Mec vito! The rear panels are steel and so If I can cut them out neatly I will have ready made panels for the job. Thank you for this video, it has given me some ideas.

[@gertc3240]

Great video as always! Disco is becoming more awesome! Thanks for showing us how easy it is, to make wing's.

[@larrybriggs2920]

Great work Nate. Really like your channel. One of the very few that do what i like to see.

[@DirtLifestyle]

Thanks man! I'm glad to hear you are enjoying the content 👍

[@mgs8747]

Hello thank you for explaining everything so well. I enjoy your videos. do it yourself is a lot of fun get your hands in there and work on stuff. Well filmed too.

[@johnyhuitron556]

Came out really good. Will look into doing this for my 02 Sequoia Limited.

[@falnere5711]

Hey Nate I enjoyed this video. I have a 95 grand Cherokee that I’ve been slowly working on and have been wanting to do this to it for the past year as well as do a custom tool box set up on both sides with additional storage below. Thanks for the video I will definitely have to look back at this when I get to that on my Jeep.

[@stephenfrost545]

Wicked guide man! I might do this on the exploder. I sold my 66 mustang and picked up an already 3" lifted suzuki sidekick, putting together a non intercooled turbo and some 31"s to start.

[@bigeasy6615]

Dude I'm wanting to do this on my Denali !!! So glad to see you making a video on it

[@simonrowlands7472]

Great window modification going to do my 3 door 300tdi got fed up of crawling through to find stuff👍

[@RecklessDevelopement]

yay! I'm doing this to my WJ, I'm walling off the sidewindows from the back at the width of the wheel wells ... give storage with easy outside access. I can't loose the daily normal family functionality of the Grand cherokee, so no full rack/drawer system for me... but a combination of the gull windows, and a slider/chuck box in place of the 40 rear split seat behind the driver (i'm 6'3" that seat behind me is pretty much useless ... however the rack will bolt in where the seat normally would, so if absolutely need to stuff one of the kids friends back there or something, we can)... That should give protected out of sight storage for everything I want to have on the rig (recovery stuff, tools, spares, base emergency provisions for exploring etc) . Literally just bought a tent trailer last night for actual camping.

[@larrysmith2137]

You come up with cool ideas. You and trail recon have fun on your trip

[@jeeper426]

that window almost looks OEM Equipment, cool idea, might even consider doing something similar on my XJ when i build the separator and roll cage

[@diymatt]

Whoooooah. I need to do this to my F350 truck cap. So much more room for activities!

[@toothless01]

I've been thinking about doing that to my Xterra. After seeing this video I'm finally motivated to get it done. Looks awesome bro, thanks for the link to get parts. 👍

[@jasonhuck3818]

Dig the Bigfoot tee shirt. And the custom work!!

[@aukanmeister]

Great project overview! I now want to build this for my 80 series👍

[@bobr7206]

Man im gonna do that to my 99 jeep wrangler hard top. And 92 explorer sport. Thanks bud for all the info

[@matsherwood6277]

I thoroughly enjoy your channel man! Thanks for another great video!

[@DirtLifestyle]

Thanks!

[@Venom-kq5xz]

That’s a nice setup! Those windows are an awesome DIY project!

[@issalawson2199]

Love the workmanship mate 👌🏽 Awesome job

[@4runner4wd79]

Very nice and inspiring! Might give it a try. Thank you.

[@TheFagatron24476]

Another great educational vid thanks Nate! Can’t wait for everything upcoming!

[@TheBeardedJeeper]

Can’t wait to see more on this build

[@DirtLifestyle]

🤘

[@srmrlr]

This was something I've been thinking about for my ZJ. Thanks, now, to see if I can plan it out.

[@the_nothing]

Oh man, I've been dreaming of this for my 4Runner for awhile

[@LiquidAudio]

Beautiful work there mate, much better than the commercially available stuff I’ve seen like the Emu Wings we have here in Aus.

[@RichyBobby611]

The latches are the same as what is used on 6k/8k/10k JLG telehandler's engine access doors. Awesome!

[@ysteintran84]

nice video. will use your chart to do this on my Volvo L3314 Laplander camper. was googling for a week now to see if i found a good how to video. thanks, keep it up! :)

[@peterwatson8295]

Awesome project!! Those turned out super well

[@ETAT230109]

Just found your channel and loving it. Given me so many ideas

[@marcustomz]

Love your videos, just a little suggestion as a body man. Try making two shims to go underneath your upper hinges to bring the window out a little bit. This will solve your tightness issue and you can go back to your original design gasket install. My 2cent nice job I wish we were Neighbors

[@derekpb6394]

Thanks for the great overview Nate... Things like this keeps that project list of to do's full ;) Looks great

[@ojbarberena7090]

I hope you don't mind but I shared it with the Nissan Patrol warriors on Facebook. Thanks for sharing

[@SWBCrawler]

Workspace Nightmare... I got that! but as of about half an hour ago.. MY JEEP RUNS AGAIN! Now to reassemble the body.. sigh. Loving the new video man, nice work.

[@SirWilliamGoes]

Awesome that turned out great. I'll be doing these for the 4runner eventually.

[@troymartin5511]

I read it as gull wing doors at first and got a little excited. 🤣

[@ericlangston481]

Love watching your channel! Learning so much!

[@shropshireladoutdoors743]

Good looking Windows look forward to the suspension mod

[@stefeniedavidmusic]

You have a hell of a nice garage there. I would kill for something like that. Hell, I would kill for just a single garage.

[@MarkHazen]

On the new Freightliner, the upper part of the doors like to separate from cab in high cross winds. I used that same exact type seal around the door to keep a tight seal. It also stopped the air whistle and any water from getting in. I think you'll be good with it. I never had a leak issue using it. Good Luck!

[@myoneblackfriend3151]

Thank you for sharing your knowledge. I appreciate it.

[@ricardoterleira]

Need these for my JK.. Well done.

[@wtforce5512]

Dude you’re killing it I hope you’re doing well I love your videos your imagination is very inspiring and your eye for what works is respectable. Great job Nate

[@joecantrell7489]

Nice job!! Looks factory!

[@DirtLifestyle]

Thank you!

[@donoberloh]

I love to hear about your upcoming conversion to 1-ton axles. I look forward to it, because I have been torn between just picking up an old live axle suburban and swap my 15oo Avalanche body onto it or swap axles with leaf springs and what ever linkage, drive shafts, etc. will be needed. I would hate to have to buy a 3/4 ton Avalanche and then swap in a live axle in front because I’ve bought this new and have owned this since ‘03 and it have always been there for me.

[@GoatOffroad]

Turned out really good Nate! ❤️🐞

[@PimptatoPCs]

Harbor Freight sells a lot of standard glass replace tools. Next time use a windshield blade with a pull handle. Spray a little soapy water around the urethane seal and it makes the job pretty easy. And if you don't have a second set of hands, just use masking tape on the outside to hold it in place.

[@trailthrillsoffroad1355]

Cant wait to see that thing rollin on 37s

[@tykethomison7676]

I see what you are doing with those wheels!

[@DirtLifestyle]

😁

[@jml7429]

“Easy” in the title. Break out the plasma cutter.

[@daleyjeeper6188]

I mean you could do the same with a cut off wheel

[@lukescido9265]

@@daleyjeeper6188 and it wouldnt bend from the heat.

[@alcopower5710]

Daley jeeper .....could have used the same jig saw he used later in the video

[@30CalCoreLokt]

Agreed. He pulled out the plasma cutter and I thought to myself... "overkill much?"

[@pappaclutch3266]

I’d rather use a cutoff wheel anyway

[@fixins]

Great project. Really enjoy your channel.

[@DirtLifestyle]

Thanks!

[@PaulKaiser42]

Really great thanks for the tips and advice on building these!!!