Doka/Single Cab Metal Engine hatch - any interest?

[keithwwalker]

The OEM fiber/plywood engine lid on my doka lasted through 2 Portland wet winters, and won't make it through a 3rd.

So I am thinking of having a metal deck lid made up to replace it.

Some of the options/features I am thinking of are:

Steel or aluminum construction, I prefer aluminum
Diamond plate or aluminum oxide grit non slip surface
Counter sunk flat recesses for the four corner bolt washers
Holes drilled to bolt or rivet the under frame that holds the heat insulation

I found a metal shop in the area that does good work.

There is a setup fee for a metal shop to do fabrication, and then a per piece charge, which could vary based on how many lids can be made from a single sheet of metal. Obviously if there is more than one lid made, then the cost per lid can go down.

If you are interested, let me know. I can draft up a drawing and get an estimate made, and post the result.

As you know, it isn't that hard to make a metal lid on the cheap for the doka, but the lid I want should have those finishing touches that I have not seen on other metal doka lids...

Please note, that if I go through with this project, I WILL NOT be ASKING for deposits or money of any kind if the interest is low.

If there is more interest than my wallet can absorb up front, then that requires more discussion.

Keith Walker

[bd]

Sounds great Keith. Just sent you a PM.
_________________
1990 2wd TriStar, Oettinger-tuned 1.6L TD

[syncrodoka]

I would be interested depending on design and price.

[Crankey]

I have a aluminum diamond plate lid. it's just sitting there held down by gravity and the friction on the rubber gasket. someday I'll make a hinge and add gas springs to it.

[keithwwalker]

OK, I will work up a drawing, then post for approval, then get an estimate. This might take a couple of weeks, work is busy right now....

I want to stay simple with this design, no hinges or gas springs.

[keithwwalker]

Preliminary info:
Hatch is 630mm width x 687 length.

Thickest diamond pattern aluminum treadplate in a Bright Finish, 3003 alloy, is 3/16 inch, and would weigh approximately 12.7 pounds.

6061T-6 diamond treadplate is available in thicker plates up to 3/4 inch (yow!), but is in a mill scale finish (if you want it shiny, polish it yourself)

for comparison sake, the square area of the hatch is 4.5 sq. ft.

Here are the weights based on different aluminum thicknesses:
3/16" = 12.7lb.
1/2" = 16.5lb.
3/8" = 24.4lb.

Another alternative is steel plate with aluminum oxide rolled into it, Alugrip for a textured non slip surface.

Here would be the equivalent weights:
1/8" = 22.5lb.
3/16" = 33.75lb.
1/4" = 45lb.

Lat alternative is Stainless Steel diamond tread plates:
1/8" = 27.7lb.
3/16" = 39.3lb.
1/4" = 50.6lb.

I don't know about anyone else, but I would rather have the thicker aluminum plate that is lighter...

If someone makes aluminum plate with aluminum oxide, I would like that too, but I haven't found a manufacturer of that so far....

[crukab]

Sounds interesting, whats your location ? Shipping will a consideration.
_________________
Tom

My Pops:
http://www.thesamba.com/vw/forum/viewtopic.php?t=604100&highlight=
I know you will always be with me, rest in peace with no more pain. 8/13/14.....

In the yard right now:
'51 Dodge 5 window truck
'65 Bug
'66 Singlecab
'82 Rabbit Truck Diesel from CALI
'86 Doublecab W/T
'91 Vanagon carat/wolfsbrg.Tiico
'88 Dodge Ram pickup
'11 Jetta Wagon

[Crankey]

I have the polished 3/16" aluminum diamond plate
when it's sitting on the rubber seal it's very close to flush with the hite of the beds ribbing.
it's also plenty strong to stand on.

[bd]

2x what Crankey said. my previous doka had the same thickness polished aluminum diamond plate, and it was bomber enough, looked good, and was the right height.
_________________
1990 2wd TriStar, Oettinger-tuned 1.6L TD

[dokarex]

I have the 3/16 diamond plate cover that blends in with the rest of my bed and is held down with 4 allen hed bolts 7/16? It works just fine need to get to the engine unbolt and move aside it came this way when I imported it from Germany

_________________
1987 Doka 1.9TD from Germany gasser DU tranny, fuel turned up, 1.6 LDA pin, boost at 15 psi,egt and boost gauges,stock diesel tach,air filter behind passenger tail light, IC to come
2006 Jetta Wagen 1.9TDI
B6200 Kubota Diesel
16ft Freestyle catamaran
16 ft Sunray 85 Horse (sunk)

[Crankey]

the thing I don't like about bolts is you can't pop the lid FAST in case of a fire (god forbid !) or some other problem.

so I just gotta make hinges and mount my gas springs someday.

[keithwwalker]

bump:
I am gonna work on drawings this weekend. I have to work out the bolt hole spacing, diameters, and corner radii.

Then I will get an estimate.

[keithwwalker]

First Draft, not to scale (right now):

I have to put in locates for the for corner engine bolts (and corresponding washer facings) and drillings for the aluminum tray that holds in the sound insulation underneath (you still have that don't you!?!) (small allen bolts will replace the rivets that will be drilled out)

I also have to check the hatch corner radii, that will come last.

If anyone can help backcheck my dimensions (in millimeters) that would be a great help!

I talked to a metal fabricator informally and they said the costing would be logically tied to the cost of a sheet of diamond plate. As of right now, that is assumed to be 48x96 inches.

That means that only 3 hatches can be made.

Ryerson's largest size is 60x144, though and with that size, 10 hatches can be made!

Thanks

KWW

[Central Syncronizer]

Anything will be an upgrade from the ugly plywood and sheetmetal lined hatch I've got now.

Jay
_________________
Ongoing restoration/maintenance of my syncro double cab (and soon Westy):

http://88syncrodoka.blogspot.com/

[bd]

shameless bump. Is there any progress on this, or any way that I can help?
_________________
1990 2wd TriStar, Oettinger-tuned 1.6L TD

[darcius]

Also would be interested. From the PNW also.

[keithwwalker]

My hard drive crashed, but I think I will be able to recover the file.

Either way, give me a couple of weeks. I will finish the drawing and see what the quotation will be.

Thanks.

btw, I am running ubuntu linux, it is a very nice system!

[bd]

cool Keith, thanks. Count me in, and please let me know if/how I can help.
_________________
1990 2wd TriStar, Oettinger-tuned 1.6L TD

[keithwwalker]

Alright, I took the rest of the measurements. I have to use a new drawing program, so give me a week or so to put the new draft up.

I also measured the heat insulator frame drillings. If it is affordable to get those drilled in, you could mod that frame to hold spare tools etc.

This could be the mother of all engine hatches...

[Bruner5]

Hey count me in on the hatch. Thanks Dan