Bay Tailgate Internal release

ElusiveStranger · Posted: Mon Aug 08, 2011 9:07 pm Post subject: Bay Tailgate Internal release

Wanna open your tailgate from the inside & find the mattress gets in the way if you use the "piece of wire connected to the lever"?

Here's a few pictures of what I've done:

Daewoo Matiz internal door handle
A nice and symmetrical fitting
I've bent the wire at the end, no where else. The loop is long enough to pass through the hole (later) so it remains as 2 widths - this stops it snagging on the box section.

Notice the white bit in this shot - this holds the metal rod

Cut out hole in tailgate (I can d/load a PDF template if people want it)
I made up a bracket that pop-rivets into the small holes. The bracket is approx 30mm wide, 20mm deep & 60mm wide (didn't take a photo)

Drilled a hole, then cut with a Dremmel. This allows the wire loop to pass through. I had to go through one of the lock screw holes to do the drilling. I smacked the "flap" inwards
Tailgates do vary - my old one was different!

Lock modification
Highly technical this bit. Weld some welding rod (or washer etc but rod's nice and smooth) onto the lock. This needs to be above the lever, anywhere else and you won't get the "throw" on the lever
Tie string onto lever and pass through loop
The "string" is kite bridle line approx 200lb breaking strain. Will use super slipery Spectra later maybe - squirt of oil will suffice for now.

There's a bit of faffing around here. Assemble the mechanism, loop the "string" through the metal rod. Take a Sharpie and mark the string where it loops. Remove string and tie a loop using the mark as a reference.

Now remove the rod from the handle. Put the string on the hook. Now carefully hook the rod to the handle - you only have 11mm of free play. Rat nosed pliers help.

Now, if you have a door card. Carefully transfer the cutout onto the back of the card. Use the trusty Dremmel to cut the backing of the panel (you can see my cut bit in photo 1)
Pull the handle out of the hole a tad - feed it through your freshly cut door card. Replace panel and screw to bracket (not shown Wink

).

Job's a good un Yes it is central!

The new Dremmel Speedclic are excellent BTW.
_________________
The advice you receive on here is worth the paper it's written on.
Your experiences are worth shed loads to others, including the f'ups - live and learn.
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'78 Bay, 2 litre 091 box, EJ20 NA & the ashtray's on the 'right' side.
I don't lean forward for hills any more Grin

Bugger, missed out on "Live fast, die young"

Alex (FTS) · Posted: Mon Aug 08, 2011 9:24 pm Post subject:

Cant see the pictures chap! But sounds like a nice littel mod!

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www.faltownskateboards.com

jp · Posted: Mon Aug 08, 2011 9:52 pm Post subject:

Looks very professional that

I'm not sure what is going on with the pics Al, seems I may have got a bit carried away with the pic uploader protections !

_________________
1971 Devon Bay with 1800 Ford Turbo Diesel Engine (wip)
1983 VW Golf GTI Campaign
1979 Mini 1275 GT
2013 Scirocco TDI GT

jp · Posted: Mon Aug 08, 2011 10:06 pm Post subject:

Think it's fixed anyone confirm?
_________________
1971 Devon Bay with 1800 Ford Turbo Diesel Engine (wip)
1983 VW Golf GTI Campaign
1979 Mini 1275 GT
2013 Scirocco TDI GT

jp

ElusiveStranger · Posted: Mon Aug 08, 2011 10:34 pm Post subject:

Hehe, I knew someone would pick up on that. Its made from a strip approx 30mm wide.
Tab at each end 20mm, then 20 deep and 60 across the "hole". Top hat cross section :-)

Can everyone else see the photos?
_________________
The advice you receive on here is worth the paper it's written on.
Your experiences are worth shed loads to others, including the f'ups - live and learn.
Wouldn't YOU rather learn by someone else's mistakes? So would they.

'78 Bay, 2 litre 091 box, EJ20 NA & the ashtray's on the 'right' side.
I don't lean forward for hills any more Grin

Bugger, missed out on "Live fast, die young"

easy-does-it · Posted: Tue Aug 09, 2011 6:26 pm Post subject:

I can see the pics Grin

Nice job ...... but...... a daewoo...?
_________________
'76 bay going superfly TDI

ElusiveStranger · Posted: Tue Aug 09, 2011 6:55 pm Post subject:

I wanted a symmetrical handle and was traipsing around a breakers opening every door I could find.
That and four switches was £10 :-)
_________________
The advice you receive on here is worth the paper it's written on.
Your experiences are worth shed loads to others, including the f'ups - live and learn.
Wouldn't YOU rather learn by someone else's mistakes? So would they.

'78 Bay, 2 litre 091 box, EJ20 NA & the ashtray's on the 'right' side.
I don't lean forward for hills any more Grin

Bugger, missed out on "Live fast, die young"