handle-free, solenoid trunk release DIY

[Garrison]

Wow, oh wow. This was a pain in the butt, but not for any legitimate reasons. I'm going to pass onto you a lot of tips to help keep the headache down to a minimum.

NEW POWER TRUNK RELEASE SOLENOID DOOR POP ACTUATOR 522T
https://sl-i.net/FORUM/images/imported/2011/10/atr15-1.gif

Let me start by saying that I began this project with a vision, a push button release that would take the place of my broken and missing trunk release lever. I wanted the button on the trunk, and I wanted it to be a clean install. I would budget at least 4 hours to fabricate yourself something worth using. It took me probably 6 hours because figuring out how to make things work takes too much time, hahaha.

Alright, so. To begin you'll need the ability to figure out problems, run wires, simple hand-tools (a drill is also helpful) as well as some scrap pieces of metal in order to fabricate some brackets, and some spare small bolts. We'll start by taking off the rear liner of the trunk hatch. It's a large gray piece that has lots of pop-rivets in it that require a deft touch in order to keep from breaking them.

Once you have the liner off, you'll be looking dead in the center for this contraption. This is where all the magic takes place:
https://sl-i.net/FORUM/images/imported/2011/10/IMAG0201-1.jpg

This is the locking mechanism. First off, that small spring in the lower right hand corner, that's either gotta go, or be replaced by something MUCH softer. This solenoid kit doesn't have the pulling power (15lbs) in order to pop the thing with this particular spring attached. Didn't figure this out until much later, learn from my mistakes.

And here's the pole I'm about to molest:
https://sl-i.net/FORUM/images/imported/2011/10/IMAG0202-1.jpg
https://sl-i.net/FORUM/images/imported/2011/10/IMAG0204-1.jpg


I heated up the pole with a propane torch and bent it with a pair of pliers, making a hook like space for the solenoid line to wrap around:
https://sl-i.net/FORUM/images/imported/2011/10/IMAG0205-1.jpg
https://sl-i.net/FORUM/images/imported/2011/10/IMAG0206-1.jpg
https://sl-i.net/FORUM/images/imported/2011/10/IMAG0207-1.jpg


Next, bend this bracket as so:
https://sl-i.net/FORUM/images/imported/2011/10/IMAG0209-1.jpg

It's going to mount like this:
https://sl-i.net/FORUM/images/imported/2011/10/IMAG0210-1.jpg

This is where the ingenuity bit comes into play, I had to drill and extend this bracket another few inches because the one sent with the kit isn't really long enough to use both bolt holes of the old handle.
https://sl-i.net/FORUM/images/imported/2011/10/IMAG0211-1.jpg
https://sl-i.net/FORUM/images/imported/2011/10/IMAG0212-1.jpg


Assembled, ready to be put in:
https://sl-i.net/FORUM/images/imported/2011/10/IMAG0214-1.jpg

Installed, loosely:
https://sl-i.net/FORUM/images/imported/2011/10/IMAG0215-1.jpg

My ground-wire (BE SURE TO SCRAPE THE PAINT AWAY TO MAKE A GOOD CONNECTION):
https://sl-i.net/FORUM/images/imported/2011/10/IMAG0219-1.jpg

I later removed this zip-tie, but this is a nice close-up:
https://sl-i.net/FORUM/images/imported/2011/10/IMAG0218-1.jpg

Had to make another bracket to accommodate my switch holder:
https://sl-i.net/FORUM/images/imported/2011/10/IMAG0220-1.jpg

And here it is installed:
https://sl-i.net/FORUM/images/imported/2011/10/IMAG0222-1.jpg

Take the remainder of the wires and run them wherever you please. I chose directly to the battery:
https://sl-i.net/FORUM/images/imported/2011/10/IMAG0224-1.jpg


I will update with more photos tomorrow, as well as clean up the remainder of the little things.
But, in all fairness to the company, it does work. And it works well. The solenoid is push button, meaning as long as the button is held, the solenoid pulls the arm and holds it down. This allows you to pull the trunk up gently and easily (precisely what I wanted). This is awesome, it just took a lot of figuring out and back-and-forth to get it working properly.

[httrdd]

Wow crazy work! You have been a busy bee..

[Wiscon_Mark]

A video would be cool :)

[Garrison]

A video would be cool :)
Gladly, here you go :grin:

https://sl-i.net/FORUM/images/imported/2011/10/th_VIDEO0002-1.jpg (http://s1003.photobucket.com/albums/af158/Garrisonbowers/?action=view&current=VIDEO0002.mp4)

[httrdd]

Thats not what you said the first time!

[Garrison]

No its not, you're right. I thought calling him a "slut" in jest was a bit uncalled for, hence the edit.

[Wiscon_Mark]

It'd be pretty cool if you wired another switch in the cabin, too! Just have to make sure that one's not easily pressed...

Maybe get a pull knob switch!

[Garrison]

It's definitely doable. The only thing you have to figure out would be how to relocate the hatch struts to actually lift the gate, as opposed to pulling it up yourself. that's why mine is where it is, because you have to have a hand on the trunk to lift it when the button is pressed.


Also, I duct-taped everything down so that stupid rattle you hear in the video from the trunk being closed is now gone.

[chuckthefuk]

Very cool!!!

This is a must for any Wagon owner with a rusty handle / lic plate lights assembly.

I am with Mark but I am lazy... Maybe one day there will be a pull latch style like the Sedans.... I know there is no tension spring so the hatch wont pop up but still :-D

Anyways good stuff!!!
-Chuck

[GTDrifter]

swap out the gas strut for pneumatic pistons

[Wiscon_Mark]

Most sedans don't pop the trunk up right away either, I was just thinking so it would be released so you could just pull up when you get back there, rather than fumbling with a switch underneath.

But that is a good idea to take it one step further. You'd just have to be careful when you do it if overhead clearance is ever an issue.

[httrdd]

What about theft? I understand that you are able to pop this even when the car is locked right? "Hey hun I just bought the kids these christmas presents in the back of the car..... wait where did they go? Damn!

[Garrison]

No, no; the trunk can only be opened when it's unlocked. When locked, it just bounces off the locking arm.

[StatGSR]

what i would do is just add a kill switch inside the car to make it so it doesn't have power just so i wouldn't have to deal with locking it manually.

btw, nice DIY!

[Wiscon_Mark]

Why would you have to deal with locking it manually? I'm sure he has power locks...

[StatGSR]

Oh right. Not everyone has a Brighton.... lol

I would like to mention though. You may want to make an access panel just I case that solinoid fails. I say this because there is no good way to remove the interior cover with the hatch stuck closed. You will basically have to destroy it to get access to the latch mechanism and it would probably look better if it was preplanned.

[Garrison]

Oh right. Not everyone has a Brighton.... lol

I would like to mention though. You may want to make an access panel just I case that solinoid fails. I say this because there is no good way to remove the interior cover with the hatch stuck closed. You will basically have to destroy it to get access to the latch mechanism and it would probably look better if it was preplanned.

Already one step ahead of you brother :wink:

Had to have the access hole in order to pop it when it was manually controlled and I had no handle.

[Garrison]

what i would do is just add a kill switch inside the car to make it so it doesn't have power just so i wouldn't have to deal with locking it manually.

I just re-read your post, and you've got a brilliant idea on manual locks. I was actually thinking about a way to do this because the electronic locks are weak in my car (dunno why, never bothered to check it out) and they don't always function properly on the first push. If I were to unplug the rear locking mechanism, or disable its actuator; coupled with your idea for a disconnect function, I would be able to keep it "unlocked" while still providing no immediate access into it without the car being open.