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DIY rear hatch interior latch
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mustard675
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PostPosted: Tue Apr 25, 2017 10:06 am    Post subject: DIY rear hatch interior latch Reply with quote

While I had the hatch taken apart to replace the windshield wiper motor I decided to install an interior latch. Again, I'm not good at taking pictures at every step but will type through the pictures I did take. Most of the material I had on hand.

1/8" flat stock 1" wide
1/8" covered braided cable
Hardware to fit, in my case I used 1/4"-20 and M6

Step 1 is to make sure that you're a hoarder. Go through your boxes of parts and find one from 2003 when you removed the interior of an 1982 Audi 4000. In this box you will find interior door handles. Part number 81183709.

Here is the test fit. As you can see the flat bar is cut to length to fit between the inside channel of the rear hatch. I initially was going to whip out the welder but decided that there was enough room to bolt the metal on instead.

Image may have been reduced in size. Click image to view fullscreen.


The Audi door handle uses the bottom factory rectangular hole, and mounts to the bar. I ended up using spacers to bring this door handle assembly forward to meet the back of the rear hatch door panel.

This lever is connected via the braided cable to the rear hatch latching mechanism.

Image may have been reduced in size. Click image to view fullscreen.


In the above photo the lock is on the left hand side. I initially tried drilling into the receiving arm to mount my own arm but that didn't have enough leverage. In the end I just fished my green cable underneath the stock spring. When this is pulled it releases the hatch mechanism. It is irrelevant whether the lock is in the locked or unlocked position. The door will open from the inside in either case.


Marking where to cut the factory panel was the trickiest part. Here I applied some wax pencil to the lock and then pushed against it with the panel to get an imprint.

Image may have been reduced in size. Click image to view fullscreen.


Once you get the location, start marking up where to cut.

Image may have been reduced in size. Click image to view fullscreen.


Cut complete.

Image may have been reduced in size. Click image to view fullscreen.


Test fit on the van.

Image may have been reduced in size. Click image to view fullscreen.


Assemble everything. In this photo you'll see that I have painted the steel. I used automotive primer and black epoxy paint I had laying around. The van hatch received some Noico 80 mil Sound deadening mat, Reflectix, and a layer of Roxul foil backed rock wool insulation.

Also, you'll notice a spring. This is a 2.5# spring to keep tension on the green wire when the mechanism is in the open position. The door handle will otherwise have some slop in it. Probably unnecessary but it also keeps the cable from going places.

Image may have been reduced in size. Click image to view fullscreen.


Install the factory panel and the project is complete.

Image may have been reduced in size. Click image to view fullscreen.


The door is a bit more heavy than it used to be with just the original fiberglass insulation. I think I will have to replace/upgrade the rear hatch struts. But overall I'm glad we have another egress point in the van while camping.
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86scotty
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PostPosted: Tue Apr 25, 2017 10:47 am    Post subject: Re: DIY rear hatch interior latch Reply with quote

Very slick. I've thought of a simpler version of this same thing like a friend of mine did on his Element using just a braided cord pulled through a hole. Yours is much nicer!
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Chainsaw
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PostPosted: Tue Apr 25, 2017 11:40 am    Post subject: Re: DIY rear hatch interior latch Reply with quote

86scotty wrote:
Very slick. I've thought of a simpler version of this same thing like a friend of mine did on his Element using just a braided cord pulled through a hole. Yours is much nicer!


Thats what an amigo of mine did on his xterra, just braided wire through a hole in the hatch so he could climb out after a night of sleep.
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r39o
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PostPosted: Tue Apr 25, 2017 11:55 am    Post subject: Re: DIY rear hatch interior latch Reply with quote

That is neat.

More of the same (from the FAQ)

https://www.thesamba.com/vw/forum/viewtopic.php?t=352626
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Gnarlodious
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PostPosted: Tue Apr 25, 2017 12:02 pm    Post subject: Re: DIY rear hatch interior latch Reply with quote

Your 2ᴺᴰ picture, I had an extension welded onto the latch lever. I put a cable through it with a crimped ferrule, the other end with a loop through a vinyl tube then crimped. Makes a simple pull handle.
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heynanc
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PostPosted: Sat Mar 14, 2020 6:37 pm    Post subject: Re: DIY rear hatch interior latch Reply with quote

It’s still well done, well explained and great help in 2020!

Thanks for the great share!
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Italjohn
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PostPosted: Wed Aug 28, 2024 12:06 am    Post subject: Re: DIY rear hatch interior latch Reply with quote

Love this, might try it myself one day Very Happy
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jimf909
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PostPosted: Wed Aug 28, 2024 10:17 am    Post subject: Re: DIY rear hatch interior latch Reply with quote

It's remarkably handy. I only have a cable snaked through a grommet in my Vangaroo but a couple of times a year I'm grateful that I don't need to run outside to open the hatch. Recommended.

Vangaroo
https://www.thesamba.com/vw/forum/viewtopic.php?t=732739&start=0
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This is the main fault with DIY'ers, they get together on these forums and pat themselves on their backs spreading bad information.
Guilty as charged.

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Alaskaberrys Premium Member
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PostPosted: Thu Aug 29, 2024 11:56 am    Post subject: Re: DIY rear hatch interior latch Reply with quote

jimf909 wrote:
It's remarkably handy. I only have a cable snaked through a grommet in my Vangaroo but a couple of times a year I'm grateful that I don't need to run outside to open the hatch. Recommended.

Vangaroo
https://www.thesamba.com/vw/forum/viewtopic.php?t=732739&start=0


Can you post a picture of your grommet cable setup with your Vangaroo?

We’re wanting to be able to open from inside and have been looking at options with our newly installed Vangaroo (which is indeed awesome!).

Door handle mod would be nice but I just can’t see it working easily without a more rigid base material.
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jimf909
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PostPosted: Fri Aug 30, 2024 8:29 pm    Post subject: Re: DIY rear hatch interior latch Reply with quote

^^^ Sure thing. I just added a grommet in the center. The cable rests between the cushion and the door. When I want to pop the hatch a tug on the cable releases the latch.

I agree that the slick door handle releases finish the job nicely but they're not compatible with the vangaroo.

p.s. I know I cut the stitches with the grommet hole punch but I'm pretty certain that I used some gluey like stuff to keep them from unraveling.

Image may have been reduced in size. Click image to view fullscreen.

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- Jim
Butcher wrote:
This is the main fault with DIY'ers, they get together on these forums and pat themselves on their backs spreading bad information.
Guilty as charged.

Current: 1990 Westy Camper - Bostig RG4, 2wd, manual trans w/Peloquin, NAHT high-top, 280 ah LFP battery, 160 watts solar, Flash Silver, seam rust, bondo, etc., etc.
Past: 1985 Westy Camper - 1.9 wbx, 2wd, manual trans, Merian Brown, (sold after 17 years to Northwesty who converted it to a Syncro).
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