DIY rear hatch interior latch

[mustard675]

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.

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.

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.

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

Cut complete.

Test fit on the van.

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.

Install the factory panel and the project is complete.

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.
_________________
1987 VW Vanagon Westfalia
@peanutbutterwestytime

[86scotty]

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!
_________________
86 Vanagon Westfalia 87k
1998 Ford E350 4x4 camper build
Vans flip flops

[Chainsaw]

[r39o]

That is neat.

More of the same (from the FAQ)

https://www.thesamba.com/vw/forum/viewtopic.php?t=352626
_________________
"Use the SEARCH, Luke" But first visit the Vanagon FAQ!

1990 Multivan EJ 22, Rancho trans 0.82 4th, Small Car front AC, CLKs w/ 215/65-16, homemade big brakes 303mm, Konis, Recaros, etc....

Click to see my ads for Cup holders, Subaru clutch fix and CLK wheels (no wheels currently)

[Gnarlodious]

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.
_________________
Vanagon ’83 diesel AAZ w/Giles injection, 5spd 4.57R&P+TBD and a '78 diesel Rabbit

[heynanc]

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

Thanks for the great share!
_________________
Nancy
2016 Subaru Outback daily driver
1984 Westfailia Vanagon EJ22 “ Guinness”
2006 Dodge Sprinter 2500

[Italjohn]

Love this, might try it myself one day
_________________
Follow me on facebook: https://www.facebook.com/norwayvanagon
My youtube channel: https://www.youtube.com/c/Italjohn
Instagram: https://www.instagram.com/italjohn/

[jimf909]

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
_________________
- Jim

[Alaskaberrys]

[jimf909]

^^^ 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.

_________________
- Jim