Rough Parts Gull Wing/MaxTrax carrier install

[Baytown]

G'day fellas.
I'm just a bit excited as today I took delivery of three large boxes of the above parts from Switzerland.
Markus at Rough Parts has been great to deal with, the Parts arrived intact, very professionally packed and superb quality.
I'll start the install early next week, once I study up on how to remove the Puma bonded side window trim and glass without damaging same. (Got a new girlfriend so that buggers the weekend up��.)
I'm not sure if my internal cargo barrier will clear the Gull Wing storage boxes, but if not, I have a mate who is a whiz at welding so he can modify the cage accordingly. It'll be tight.
I thought I'd do a seperate install- instalment vs placing this thread in the 'What did you do to your Puma today' thread.
I hope it's of interest.
Photos of the install to follow next week.
Wish me luck!
Ken
http://i1037.photobucket.com/albums/a452/47Indian/IMG_2747.jpg (http://s1037.photobucket.com/user/47Indian/media/IMG_2747.jpg.html)
http://i1037.photobucket.com/albums/a452/47Indian/IMG_2752.jpg (http://s1037.photobucket.com/user/47Indian/media/IMG_2752.jpg.html)
http://i1037.photobucket.com/albums/a452/47Indian/IMG_2754.jpg (http://s1037.photobucket.com/user/47Indian/media/IMG_2754.jpg.html)

[tonyci]

Look forward to the update Ken, should look great. Good luck with new girl friend as well I hope she knows what she's up for going out with a Defender owner ?.
Cheers
Tony

[El Rey]

Looking forward to seeing this installation

[filcar]

...Got a new girlfriend so that buggers the weekend up ...
[/IMG]


If you spend half as much on her as you do on your Defender she'll be a happy girl ;)

[Tombie]

Good luck Ken!

A Girlfriend and a Mistress (Defender)...[emoji6]

[Baytown]

Gday Fellass.
Thanks for the comments. She does complain about how high it is to get into the truck. I've got Titanium knees and I can manage!
I have looked at some other threads in the UK re removal of the bonded side glass and trim.
This seems to be the go.
It has a handle which is at right angles to the trim/glass, a handle and leed to pull the blade which is guided by a wheel.
Clever, as well as a wire saw etc.
I'll report back on how it goes once it arrives (only $40 Aussie Sheckles) but it would have to be the tool to use.
Ken
http://i1037.photobucket.com/albums/a452/47Indian/IMG_4476.png (http://s1037.photobucket.com/user/47Indian/media/IMG_4476.png.html)

[Baytown]

I thought I'd start dismantling the back of my truck this afternoon and begin the mongrel job of removing the bonded side rear windows and trim.
Got the interior trim out, and almost took my right index finger off with the Stanley knife, drops of blood on the side of the truck and everything!
I then resorted to using my Bosch vibrating saw with a silicone cutter blade.
It worked well for the side and lower access, but won't clear the rain channel on the upper side.
Off to Bunnings in Cairns to see what other blades they have.
Even being careful, I've scuffed some of my paint, so will repair this accordingly before I install the Gull Wings.
All in all, the removal of bonded rear side glass on a Puma is officially a Bastard of a job.
More to follow.
Ken
http://i1037.photobucket.com/albums/a452/47Indian/IMG_4633.jpg (http://s1037.photobucket.com/user/47Indian/media/IMG_4633.jpg.html)
http://i1037.photobucket.com/albums/a452/47Indian/IMG_4634_1.jpg (http://s1037.photobucket.com/user/47Indian/media/IMG_4634_1.jpg.html)
http://i1037.photobucket.com/albums/a452/47Indian/IMG_4635.jpg (http://s1037.photobucket.com/user/47Indian/media/IMG_4635.jpg.html)

[Baytown]

http://i1037.photobucket.com/albums/a452/47Indian/IMG_4622.png (http://s1037.photobucket.com/user/47Indian/media/IMG_4622.png.html)
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http://i1037.photobucket.com/albums/a452/47Indian/IMG_4627_1.png (http://s1037.photobucket.com/user/47Indian/media/IMG_4627_1.png.html)http://i1037.photobucket.com/albums/a452/47Indian/IMG_4628.png (http://s1037.photobucket.com/user/47Indian/media/IMG_4628.png.html)
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http://i1037.photobucket.com/albums/a452/47Indian/IMG_4631.png (http://s1037.photobucket.com/user/47Indian/media/IMG_4631.png.html)

[dazzler]

I like this shop ...now you are going to cost me money Ken!! good luck with the windows, I find them very useful

[Dervish]

I've had success removing Puma windows with an el cheapo bread knife. Nice long flexible blade and the serrations make a lot quicker work of the glue than a flat blade.

[Baytown]

Thanks Dervish.
I've still got to get through the upper bead of Mastic. The only knifes that would fit were snap off type which all "snap off" I'm more than frustrated with this.
I'll go into town and buy a cheap bread knife or the like. Now that you have me thinking, a fishingfillet type knife may be an option as well.
Thanks again mate, I just may be able to get that window out today!
Best wishes.

Ken

[Baytown]

Well, after not being able to buy a suitable bread knife in Innisfail after 12 on a Saturday, and breaking the $30 filleting knife, as well as most other snap type blades etc, ruining some Steak knives as well, I finally got the bloody thing out.
I can't believe how difficult that job is.
I've got a 90 deg vibrating blade coming from the US as couldn't find any in Cairns either for my Bosch tool.
Hopefully this will make the left side a lot easier.
Removed the remaining Mastic with a scraper ( broke that as well!)
Primed the scratched duco around the glass cut out with etch primer and will let that dry overnight before giving another coat.
Let that dry tomorrow,paint with something that approximates silver from a can, then look at fitting the right side Gull Wing box and panel. I'll have to wait till I've got a helper for that as there's adhesive and drilling the panels involved.
More to follow.
Ken
http://i1037.photobucket.com/albums/a452/47Indian/IMG_2791.jpg (http://s1037.photobucket.com/user/47Indian/media/IMG_2791.jpg.html)

[weeds]

Maybe taking the roof off would be easier??

[Baytown]

If the rain channel went with the roof, it would.
The gutter really does make getting any of the blades I've been using really a problem. (That, and my attention span of a gold fish!)
Hopefully the vibrating 90 deg tool blade will get around it for the remaining window.
I'm done for the day and I'm out of Scotch. Looks like a mercy dash into town!
Good on you Weeds.
Ken

[dazzler]

G'day Ken have you considered using a thin steel wire to slice through the compound?

[D90 orkney]

G'day Ken have you considered using a thin steel wire to slice through the compound?

Awesome idea!

Il be trying that when I do mine. Perhaps something like this?

Windscreen Cutting Wire (http://www.allwarehousesupplies.com.au/buy/windscreen-cutting-wire/WK300-WIRE)

[weeds]

If the rain channel went with the roof, it would.
The gutter really does make getting any of the blades I've been using really a problem. (That, and my attention span of a gold fish!)
Hopefully the vibrating 90 deg tool blade will get around it for the remaining window.
I'm done for the day and I'm out of Scotch. Looks like a mercy dash into town!
Good on you Weeds.
Ken



Sorry meant to be tongue in cheek.....

[Witchdoctor]

Baytown,
Have a peek at my post on all this, just may help

Dave

[D90 orkney]

Guys would this work? I guess the problem would be feeding the line through to the other side. Could it be feed through? Maybe if you drilled a hole from the inside on an angle through to the outside you could expose a section and pry it through. That's if you aren't keeping the window

https://youtu.be/roROADrS5m4

Or perhaps this blade on a multi tool?

https://www.gtglass.com/auto-glass-replacement-tools/auto-glass-hooked-oscillating-blades-63mm

[Baytown]

Hi fellas.
Dazzler:
Yes, I've got the wire cable and handles. The wire needs to travel up an inch of the outside of the panel, right angle at the lip, then down the inside. In my case it breaks every few inches, and after resetting the cable about 7 times, I gave it up.
I think the best bet is the Bosch vibrating saw. I've got Silicone blades which work great on the lower edge and sides, but won't clear the cutter on the top.
I can wait for my blade to come from the US as I've a fair few other jobs I can get into.
Dave, I certainly will, thanks mate.
Weeds, I knew that mate, but I tell you what, if it were easy, I would have lifted the roof!
Good on you fellas.
Ken

[dazzler]

Yes multitool will work, but I was thinking in line of balustrade wire rope or similar which wont break when it comes in contact with the panel. Anyways good luck with it all, I have a pair of CSW's and they are very handy.

Regards

[Witchdoctor]

Baytown,

I would advise against the vib tool, you will find it will cut into the body panel.
This coming from experience

Take the time & read my post on installing gullwing doors.
We share our experiences to assist other.

Enjoy the adventure

Dave

[Baytown]

The cut out painted silver and ready for test fitting of the Gull Wing box, so as to accurately mark the holes for drilling.
http://i1037.photobucket.com/albums/a452/47Indian/IMG_2796.jpg (http://s1037.photobucket.com/user/47Indian/media/IMG_2796.jpg.html)[/IMG]
The box ready to be test fitted.
[IMG]http://i1037.photobucket.com/albums/a452/47Indian/IMG_2795.jpg (http://s1037.photobucket.com/user/47Indian/media/IMG_2795.jpg.html)[/IMG
The cut out primed and painted, ready for Sikaflex bond and drilling.

[Witchdoctor]

You may need to file those tabs off in the opening radius.

Just sent you a PM

Cheers

[Baytown]

Now I'm starting to make headway.
Thank you Dave (Witchdoctor) and Tony from Defender2.net for your assistance fellas.
I fitted the external frame and locking panel today, but it was too warm to do any more. The Sikaflex was going off very fast so not much time to adjust things or easy clean up of any extruded sealant.
I ran two beads of Sikaflex Auto body adheasive - sealant on both sides of the upper and lower faces, and three on the ends as there was more space.
I'll mount the internal storage box tomorrow, and hopefully the fold down table and MaxTrax carrier.
I'm very happy with the fit, quality and finish of the Rough Stuff product.
More pics to follow hopefully tomorrow.
Best wishes fellas.
Ken
http://i1037.photobucket.com/albums/a452/47Indian/Mobile%20Uploads/2017-02/D8DB409B-C1AE-4637-A734-CC9FD0242607.jpg (http://s1037.photobucket.com/user/47Indian/media/Mobile%20Uploads/2017-02/D8DB409B-C1AE-4637-A734-CC9FD0242607.jpg.html)
http://i1037.photobucket.com/albums/a452/47Indian/Mobile%20Uploads/2017-02/D23DEDD5-246E-418E-A2A8-851D0907B00F.jpg (http://s1037.photobucket.com/user/47Indian/media/Mobile%20Uploads/2017-02/D23DEDD5-246E-418E-A2A8-851D0907B00F.jpg.html)
http://i1037.photobucket.com/albums/a452/47Indian/Mobile%20Uploads/2017-02/C9083A27-5589-4FF2-A7F3-AA4933FED26C.jpg (http://s1037.photobucket.com/user/47Indian/media/Mobile%20Uploads/2017-02/C9083A27-5589-4FF2-A7F3-AA4933FED26C.jpg.html)
http://i1037.photobucket.com/albums/a452/47Indian/Mobile%20Uploads/2017-02/D3F5EC57-4196-4018-923E-45BE726AA199.jpg (http://s1037.photobucket.com/user/47Indian/media/Mobile%20Uploads/2017-02/D3F5EC57-4196-4018-923E-45BE726AA199.jpg.html)

[D90 orkney]

Any tips BT on the removal?

[Baytown]

Lots of protection tape.
You'll notice the scratch down my panel. I wasn't even cutting near it. The handle did this.
Bottom and sides aren't a real issue, the top run of Mastic is an absolute mongrel.
Tools:
Long, thin, malleable blades. Snap off types will snap off under the window frame and frustrate you.
Dave suggested a small trowl sharpened and bent so as to get between the gutter and the sealant. Where able, lever the sill surround away from the body.
Soapy water to lube the blade against the Mastic, though Tombie probably has something in his beside draw that would work better��
Take your time, a few cm at a time.
Also cut away any sealant from inside the vehicle.
I'm also going to try a throw away bread knife as suggested for the top run on my left side which I still need to remove.
I would suggest that my Rough Parts Gull Wing fits differently to Front Runner items. I didn't have to trim the four mounting tabs in my window frame.
Do it on a cool day, as it's a hell of a job in the heat.
I managed by myself, but an assistant would help when mounting-drilling the bolt holes for the Gull Wing.
Lots more protective tape.
Maintain a sense of humour!

[D90 orkney]

Lots of protection tape.
You'll notice the scratch down my panel. I wasn't even cutting near it. The handle did this.
Bottom and sides aren't a real issue, the top run of Mastic is an absolute mongrel.
Tools:
Long, thin, malleable blades. Snap off types will snap off under the window frame and frustrate you.
Dave suggested a small trowl sharpened and bent so as to get between the gutter and the sealant. Where able, lever the sill surround away from the body.
Soapy water to lube the blade against the Mastic, though Tombie probably has something in his beside draw that would work better��
Take your time, a few cm at a time.
Also cut away any sealant from inside the vehicle.
I'm also going to try a throw away bread knife as suggested for the top run on my left side which I still need to remove.
I would suggest that my Rough Parts Gull Wing fits differently to Front Runner items. I didn't have to trim the four mounting tabs in my window frame.
Do it on a cool day, as it's a hell of a job in the heat.
I managed by myself, but an assistant would help when mounting-drilling the bolt holes for the Gull Wing.
Lots more protective tape.
Maintain a sense of humour!

Sounds like a fun time!

I've ordered my front runner glass gullwing. So I'm going to go through this awesome procedure soon.

For the top would running fishing line across the top and running it back and forth work? Sort of like a cross cut saw process?

[Baytown]

If anyone purchases the Rough Parts Gull Wing box, you need to attach your quick fists etc before bolting the box into your Defender. You can't get the perforated mounting panel out of the box after installation.
I'll certainly take this into account when I fit the left side box next week re my kitchen gear.
Trap for young players!
I did manage to mount my tomahawk via quick fists with a lot of mucking around, but used chain lock from Bunnings for the other gear which worked well.
Ken
120196

[weeds]

How do you find reaching across the fold down part??

[Baytown]

Hi Weeds.
Not an issue, and I can easily reach all areas of the contents.

Ken

[weeds]

Hi Weeds.
Not an issue, and I can easily reach all areas of the contents.

Ken

Goodo, bit hard to tell from the shot.

[Baytown]

I promise I'm not made like an Orangatang!

[El Rey]

I promise I'm not made like an Orangatang!

Reminds me of my old Fiat ownership days and the Italian Ape driving position.
Built for people with short legs and long arms apparently!

[Baytown]

I couldn't be buggered going through the pain of removing the left side glass myself.
Local auto glass people, 30 mins, not a mark on the paint and $60!
Guess what I'll be doing this weekend?
Just do it!

122918

[karlz]

You should have looked at my thread before you started.

CSW Gullwing into 2015 Puma Defender (https://www.aulro.com/afvb/90-110-130-defender-county/238816-csw-gullwing-into-2015-puma-defender.html)

[komaterpillar]

Only 60 bucks to remove one of those bastards, after doing both of mine I reckon next time I'd just pay the money
well done!