Barn-door To Tailgate Conversion

[djmeeg]

So I used that as a reference to figure out which wire did what in the barn door loom to thrn take out the pins and Put them in the config as per tailgate.

Is there a way I can check perhaps ? Van is all done so finding rear loom connector will be hard and buried somewhere behind everything.

 

[HoopDub]

So did you run 2 extra wires from the connector to the bcm in the dash?

 

[djmeeg]

Hi, I don’t remember doing this. I wondering how I can check, do I need to pull out the bcm under the dash and check the connector to see if I ran somthing to the pins you mentioned previously.

What gets me is that using vcds I can see that the van knows whether the tailgate is open or closed. It will also trigger the actuator on the tailgate which would unlock it ! But it will only do this if I have the tailgate open.

So why would the van only unlock when it’s only unlocked

 

[HoopDub]

Hi, I don’t remember doing this. I wondering how I can check, do I need to pull out the bcm under the dash and check the connector to see if I ran somthing to the pins you mentioned previously.

What gets me is that using vcds I can see that the van knows whether the tailgate is open or closed. It will also trigger the actuator on the tailgate which would unlock it ! But it will only do this if I have the tailgate open.

So why would the van only unlock when it’s only unlocked

To be honest, if you don't remember doing it, chances are you didn't. It's not a 5 minute job, to run the wires you have to take down the headlinging throughout, the A pillar trim, lower dash trim, etc etc.
So, no matter how much coding you do it will never work. Having it partially work in certain circumstances is a sign that kind of backs up the probability of it being wiring.

 

[Mickm]

Here's the difference at the hinge mounting points on the van....

Barn/wing doors,
View attachment 254313


Tailgate,
View attachment 254314

As you can see, i did get around to washing the area

A 300% thicker mounting area on an additional full width cross member for tailgate vans over the barn/wing door vans.

Hi @HoopDub - great work!
I have both inner and outer panels and I made a start this week.
Rear headlining down, carpet lining removed, all spot welds located and centre punched.
Do you have any photos of the adapted inner member or the member in place please?
Thanks,
Mick.

 

[HoopDub]

Hi @HoopDub - great work!
I have both inner and outer panels and I made a start this week.
Rear headlining down, carpet lining removed, all spot welds located and centre punched.
Do you have any photos of the adapted inner member or the member in place please?
Thanks,
Mick.

Hi mate, i didn't take any of the panel after I'd chopped it, as it was a suck it and see mission. But these show the areas i cut.
The entire panel in half was the first.

Then the end's had to go as these would be between the side panel and roof, an impossible task retrospectively.

The third cut was to remove the indent area above the hinge plate, there was no way to slide the panel in place with this intact.

Hard to explain, but im sure you will see what i mean when you get to this stage.
You will need some weld through primer and some panel bond. And plenty of clamps and grips.

 

[Mickm]

Hi mate ok that’s great info and pictures!
Thank you!
Ill post any updates and pics to help others, cheers

 

[Mickm]

Hi mate, i didn't take any of the panel after I'd chopped it, as it was a suck it and see mission. But these show the areas i cut.
The entire panel in half was the first.
View attachment 254549
Then the end's had to go as these would be between the side panel and roof, an impossible task retrospectively.
View attachment 254550
The third cut was to remove the indent area above the hinge plate, there was no way to slide the panel in place with this intact.
View attachment 254551
Hard to explain, but im sure you will see what i mean when you get to this stage.
You will need some weld through primer and some panel bond. And plenty of clamps and grips.

Hi mate can I ask which panel bond you used please? I know TPS do a single part tube version? Thanks

 

[HoopDub]

Hi mate can I ask which panel bond you used please? I know TPS do a single part tube version? Thanks

Any PU adhesive will do mate it's not a structural/impact area. It's mainly for anti vibration. I plastered it everywhere where the panels were touching or could touch. Nothing worse than pumping out some loud reggae and hearing panels vibrate

 

[Mickm]

Snap



The above photos with red lines are pretty bang on! Thank you

 

[HoopDub]

View attachment 255370

View attachment 255371

Holy metal fatigue batman!!!

 

[Mickm]

Holy metal fatigue batman!!!

 

[Mickm]

It’s very doable if anyone is worried

 

[plink]

It’s very doable if anyone is worried

As the owner of a barn door T5.1 converted to tailgate , i do find this quite worrying. I removed stronger gas struts i had purchased for the double glazed California tailgate i had fitted a while ago as i noticed a lot of flex in the areas around the hinges... My van is now fully converted with a pop top roof fitted. I wonder how possible it would be to fit the new tailgate strengthening panel with a pop top roof/frame etc in place.....

 

[Mickm]

As the owner of a barn door T5.1 converted to tailgate , i do find this quite worrying. I removed stronger gas struts i had purchased for the double glazed California tailgate i had fitted a while ago as i noticed a lot of flex in the areas around the hinges... My van is now fully converted with a pop top roof fitted. I wonder how possible it would be to fit the new tailgate strengthening panel with a pop top roof/frame etc in place.....

I would say that structurally this area is unaffected by your pop top.
I’m guessing you will have some interior ceiling trim to remove and maybe a section of your units/cupboards at the rear…

 

[plink]

I would say that structurally this area is unaffected by your pop top.
I’m guessing you will have some interior ceiling trim to remove and maybe a section of your units/cupboards at the rear…

Yes, i think you may be right....i'll have a closer look at my van today and see whats involved. Do you know if the part numbers mentioned, 7E1817203 and 7E1817203
are also good for a T5.1?

 

[Mickm]

Yes, i think you may be right....i'll have a closer look at my van today and see whats involved. Do you know if the part numbers mentioned, 7E1817203 and 7E1817203
are also good for a T5.1?

I would say they will be the same but to be sure I would find the registration of a factory tailgate T5.1 and take that to TPS when ordering your parts…unless anyone on forum can confirm…

 

[plink]

I would say they will be the same but to be sure I would find the registration of a factory tailgate T5.1 and take that to TPS when ordering your parts…unless anyone on forum can confirm

Yes that was a good idea and I tried that with a T5.1 tailgate reg, but the parts centres say that whilst the part 7E0817164D is coming back as ok, part 7E1817203 (7H1817203C) Is not. I'll try and investigate further but its a stumbling block at the moment.

 

[HoopDub]

Yes that was a good idea and I tried that with a T5.1 tailgate reg, but the parts centres say that whilst the part 7E0817164D is coming back as ok, part 7E1817203 (7H1817203C) Is not. I'll try and investigate further but its a stumbling block at the moment.

Both parts will fit a T5.1. 7H1817203C part has been used (according to etka) on tailgate models since the T5 was introduced.

 

[HoopDub]

I got my tailgate on. Rather difficult on your own
It went quite smoothly untill it came to the retrofit strut brackets. They haven't been folded enough in manufacturing so i cant bolt them to the van!!
What a PITA!!!