MK3 Hatch Popper DIY, enjoy!

[xtremevdub]

Ok.. since someone started a thread asking about doing this mod.. and I had everything I needed for the last year,
I figured I will finally get it done.

First Run the wire..
I used a thick speaker wire when I did my rear fog setup.. and left the other piece of wire to do this mod a year or so ago..
I would do the same If I was you, since you will have everything needed to have the reverse fogs hooked up.

Basically, run the wire from inside the car (behind the radio area) to the drivers A pillar, then go past the B and C pillars into the hatch.

You will have to take all the little trim pieces of the hatch to run the wire.
A coat hanger will come in handy.

You wanna make sure you go thru the rubber boot like this pic.

Here is what it looks like when the wire is thru...

and connected to the Reverse Fog.

You will find a nice place for your grounds inside the hatch.

On that pic you can see the vacum pump that "pushes" the little stick allowing you to open the hatch.
You'll undertand when you are there.

closer pics of the mechanism.

Basically.. you could push open the latch stick or you could open the key lock. is your call.
I decided to push the latch open and retain the factory vacum pump.

On another note.. this would also be a great time to remove the 3rd brake light and shave the letters and smoke it.

Then you need to go and get your popper..

there are basically 2 types on the mk3's

A puller and a pusher.. you need the pusher.

You will probably need these.

ok..
on to the install...

I mocked the popper on the driver side of the hatch.. using the mk3 "black plastic stick" to push the latch open....

now.. that black plastic stick has a snatch that fits the top of the latch.
So I put it on top and used a zip tie to get it together.
(make sure you dont tighten the zip tie too much. It needs to be kind of loose and the black plastic needs to allow the latch to move by itself)

then began making a bracket made out of cardboard.
After I had what I needed, I made one out of metal.

when it was tested and working fine..
I wrinkeled it..

Final product...

Then I soldered and heat shrinked the in-line fuse that I was gonna use...

And soldered the rest to the Speaker wire on the car..

Note....
I used a 5amp fuse.. just to see if it pops it, but I really dont think so..
I rather pop a fuse than melt the wire.

pics of the setup already wired and in the car..

Again..
I used the grounding points for my ground.

Make sure to grease up (lithium grease) your black stick and zip tie so everything moves smoothy.

So far so good, no?????
Well not so easy....

When I finally closed everything and went to actually close the hatch
(not manually test it presing the latch in with a screwdriver)

the damn hatch would not close..
I was messing with it for a while and then I noticed that this part was the culprit.

Since the popper was just on top of it, I guess the bracket put a little pressure on it and would not let the spring compress all the way.
So... I took the bitch out.

Funny how years ago I made sure to buy it, never noticed much difference with it on.. and now that I take it out, it works best.

Final toughts.
If I was to do this again.. I would redo the bracket to get a little better of an angle, since that spring wont be there.
OR
I would mount the popper closer to the drivers side tail light and run a long mental stick all the way to the latch release.

Now on to the wiring of the switch.

To be continued.......

[NoCYet]

Nice write up so far. I like the custom bracket, but without the springloaded popper you removed, when you push the button it will work the latch, but that part needs to be there to pop the hatch up a bit, otherwise I'm pretty sure it will just latch again when you release the button. Just my 2cents.

[xtremevdub]

Quote, originally posted by NoCYet »

Nice write up so far. I like the custom bracket, but without the springloaded popper you removed, when you push the button it will work the latch, but that part needs to be there to pop the hatch up a bit, otherwise I'm pretty sure it will just latch again when you release the button. Just my 2cents.

You would think that would make sense.. but it actually doenst..
The hatch opens perfectly fine.. actually better than with the spring thingy in..
Just to give you a perspective... no mk3 came with the "spring loaded thingy" and they never had an issue with opening their hatches.

Hell, I am willing to bet that most people here dont even have that part in their cars anyways.

By the way.... I dont recall that switch being iluminated.. but it seems to have 3 prongs in it.. what gives?

[emg60vw]

pics not working.

[NoCYet]

Quote, originally posted by xtremevdub »

You would think that would make sense.. but it actually doenst.. The hatch opens perfectly fine.. actually better than with the spring thingy in.. Just to give you a perspective... no mk3 came with the "spring loaded thingy" and they never had an issue with opening their hatches.

Well, in that case.

[xtremevdub]

ok.. since DIY dont get much love anymore..
I am thinking of building a complete kit.. contact me for details.

[DUBZAK]

I missed this...Awesome work, ill just run another cable from the pusher to the button and tie this into my keyless write up!

[MikkiJayne]

Quote, originally posted by xtremevdub »

Hell, I am willing to bet that most people here dont even have that part in their cars anyways.

Nope

[NoCYet]

Quote, originally posted by xtremevdub »

Hell, I am willing to bet that most people here dont even have that part in their cars anyways.

I keep buying them, and they keep breaking, kind of a metaphor for the whole Corrado experience.

[xtremevdub]

Quote, originally posted by NoCYet »

I keep buying them, and they keep breaking, kind of a metaphor for the whole Corrado experience.

hahaha. damn corrados... and here I am thinking on getting another one..

[where_2]

Quote, originally posted by xtremevdub »

hahaha. damn corrados... and here I am thinking on getting another one..

You need atleast one Corrado for each hand, or one for every day of the weekend...

Nice writeup as usual. If you don't need that spring thingy, send it my way... I broke mine in 1998.

[Noobercorn]

Quote, originally posted by xtremevdub »

a long mental stick

lol @ "mental"

great write up!! this should be in the FAQ's.

[xtremevdub]

Quote, originally posted by Noobercorn »

lol @ "mental" great write up!! this should be in the FAQ's.

ha! I missed that one! ..

Part 2 of this write up is coming soon.. may be tomorrow.. I am missing the damn plug for the hatch switch.
I am thinking of mounting it by the side/front of the E-brake.
or on a dummy plug on the dash.. we'll see.
I am gonna pick it up today and make another bracket, since I designed the one on the car to work with that spring thingy.

[xtremevdub]

ok... as usual took longer than spected... I had to make a switch, just because I Think I have OCD..

I will be making a revised bracket soon also.. for the same reasons above.

And another switch, because that one as nice as it looks and works, (push style now, no longer rocker style) doenst light up

[xtremevdub]

Here is the revised version of the switch.. This one lights up.







As per strangevolk request!

[WhoUtink]

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I was messing with it for a while and then I noticed that this part was the culprit.

I had this part in the plastic parts and screws not attached to car when I bought it and had no clue what it was until now, but the hatch opens just fine.

[NoCYet]

I had this part in the plastic parts and screws not attached to car when I bought it and had no clue what it was until now, but the hatch opens just fine.

All it does is bump the hatch up a little when you pop it to make it easier to grab ahold of. I mounted my popper in a different location, and kept it. It really doesn't matter.

[petethepug]

You'll have to get a led glow fuse in there. That fuse is deff in a place I'd want a visual que the fuse is blown and not have to reach in and check it.



If you made a kit I'd think you could get a few more bucks if it had one these in it.