ACTIVE: B5/B.5 Stainless Self-opening Trunk Hinge Mod - Page 2

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Thread: ACTIVE: B5/B.5 Stainless Self-opening Trunk Hinge Mod

  1. #31
    Moderate Moderator Steve in Chicago's Avatar
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    In the above video, if you crank up the resolution to 480p or better, you can watch it in 3D! (I gotta get a pair of those glasses now)

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  3. #32
    SuperCooled30V Moderator keithwbloom's Avatar
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    New and improved spring design, better than OE Audi parts!

    I have learned a great deal more about spring design in the last few weeks than I ever dreamed existed. Apparently, the OE Audi part springs are not ideal for the trunk hinge mod because they are not designed to be installed under tension with a full 25mm of deflection. What is deflection you say? Here's a primer:


    • deflection |diˈflekSHən (engineering), the displacement of a structural element under load — in spring language, how far the spring is stretched from it's resting length when under tension.


    I won't go into all the other terms. Suffice it to say, the Audi OE springs will eventually lose efficacy because they are deflected 200% of their structural limit in the hinge design as spec'd by the German wizards at PassatPlus.de. Under such a continuous load, the springs stretch and eventually "set" in an elongated, less effective state. Not something they shared in followup to their posting of the design, but probably why their design spec'd the additional Audi buffers to push the lid up with a pop initially when the latch is released.

    So here's where my spring designer and I have made the breakthrough. I shared with him my design and the deflection requirement, and the actual force requirements of the design. I even added some extra oomph to my lift calculations thanks to SteveInChicago who posited that he has both a Votex spoiler and warning triangle installed on his boot lid, thereby making it heavier.

    The end result is that we came up with a spring design that is better suited to the mod, and will not stretch over time due to being installed with a constant 25mm deflection. This means that the springs will be as strong on day one as they will be on day three hundred and one, and for years after that. And it means no one will have to supplement their hinge assists with OE Audi buffers.

    How was this done? The new springs are of a slightly heavier gauge wire, and are wound with a slightly larger coil diameter with a modest preload. I promised I wouldn't go into all the other terms, but there I went ahead and used them. In plain English, the wire is thicker and the barrel part of the spring is a little fatter. They will again be made of carbon steel, tempered and finished in black oxide for a tidy look, especially in contrast to the brushed stainless brackets and hardware, and to protect against rust.

    OK, so the "tell you like it is" part of me is twisting my arm to finish my lesson in spring design dynamics. Springs strength and performance characteristics are dictated by four factors: 1) wire gauge, 2) type of steel, 3) number and diameter of coils and 4) preload. Safe deflection range of any spring design is a formulaic calculation. The Audi OE springs and the original copies I had produced do not have the needed characteristics to survive under constant deflection of 25mm (stretch applied to springs when trunk lid is closed.) The new ones do, with a little breathing room, just to be sure.

    Thanks to the early adopters for helping me test installations other than my own. Your new springs are in production.

    B7 S4 Cabriolet 6MT, 8P A3 Tip, B5.5 SC/IC V6 5MT

  4. #33
    Moderate Moderator Steve in Chicago's Avatar
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    Who would go to this length to "get it right"?

    You rock, Keith!

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  6. #34
    SuperCooled30V Moderator keithwbloom's Avatar
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    Quote Originally Posted by Steve in Chicago View Post
    Who would go to this length to "get it right"?

    You rock, Keith!
    Thank you very much. I'm here all week. Tip your waiters.

    I just noted you were in 6th Gear. Did you do a tranny swap on your B5?

    B7 S4 Cabriolet 6MT, 8P A3 Tip, B5.5 SC/IC V6 5MT

  7. #35
    SuperCooled30V Moderator keithwbloom's Avatar
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    Testing springs one more time before finalizing replacements

    I sent a kit to Steve in Chicago to install on his B5. He has a Votex spoiler and VW/Audi safety triangle installed on his boot lid, so I have asked him to install with the rev. 1 springs to be sure that they can pull the extra load before I order redesigned spec replacements for all the new kits and the springs sent with original kits.
    B7 S4 Cabriolet 6MT, 8P A3 Tip, B5.5 SC/IC V6 5MT

  8. #36
    SuperCooled30V Moderator keithwbloom's Avatar
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    Installation Instructions

    Some better photos and step-by-step with notes. For my photos, I used a hinge I had on my bench. In addition to being more photogenic, I found it far easier to mod the hinges this way, albeit it adds about 15 minutes to the install time because you have to remove and then reinstall the hinges from the car. If you have a friend to help you, you can probably lay the lid back against the back window on a blanket while you mod the hinges off the car so you don't have to unplug the electrical connectors going to the license plate lamps and trunk lock release.

    NOTE: some of the sequence pictures show the hinge arm extension without the spring mount post attached. You need not disassemble your kit that far to install. Just slip the spring from the grommet on the hinge arm side to make it easier to handle. It can be reassembled as shipped to you once the hinge arm extensions are mounted.

    1. A view of the driver's side hinge removed from the car.
    2. Using a sharp punch, mark the first hole on the center of the ridge about 6mm from the mid point of the rounded bend (where the shop light reflection looks like a "/" to left and below the punch tip in this photo).
    3. With a 1/8" HSS bit, carefully drill a pilot hole through the hinge arm, making sure your drill tip does not "crab" out of position. A deep punch mark will keep it tracking perfectly.
    4. When the pilot hole is complete is will look like this.
    5. Next, increase the size of the pilot bore to 1/4" with a HSS bit.
    6. Using one of the M6x10mm screws, loosely attach one of the hinge arm extensions through the hole shown, and position the second hole over the center of the ridge further down the arm.
    7. Using the sharp punch tool, mark the exact center of the second hole position on the hinge arm. Because I finish these pieces by hand, sometimes the distance between the bores the hinge are extensions is slightly different from piece to piece. By installing in this method, the brackets will be an exact fit.
    8. With the center clearly marked, remove the hinge arm extension and punch the mark firmly to make a good pilot hole. Using the 1/8" HSS bit, drill the second pilot hole.
    9. Visually check the accuracy of your pilot bore with the hinge arm bracket.
    10. Increase the size of the pilot bore to 1/4" using a HSS bit.
    11. If you have a round file, you might want to smooth down any roughness in the bores after you have finished the second one.
    12. Loosely install the hinge arm extension through the second hole using one of the M6x10mm screws.
    13. Loosely test fit the second M6x10mm screw. They are usually very close, and sometimes they touch, which is okay. Once we install the top bracket and spring standoff, we will tighten these down in sequence from left to right as shown in this photo.
    14. A view of the reverse side of the hinge arm extension with the mounting screws in place.
    15. Because the spring will be under too much tension to attach the boot lid anchor with the spring attached, remove mounting screw from the position shown and loosen the other a wee bit to allow the extension arm to pivot easily.

    16. Note: repeat this same installation sequence in mirror for the other hinge, and then if you have removed the hinges from the car to do these step to this point, reinstall them on the car. The following sequence shows steps that should be done once the hinges are on the car with the hinge arm extensions in place, however, for continuity, the photos were taken while hinge was still on my workbench.
    17. Once the hinge has been reinstalled on the car and the boot lid attached, using a 13mm deep socket or a 13mm socket with a stubby extension, remove the lower flange nut and use it to install the boot lid anchor and pivot arm assembly as shown.
    18. With the boot lid anchor attached, pivot the hinge arm extension with the spring now under modest tension, until the second mounting holes line up. Restore second mount screw (lock) into position and tighten in sequence, pivot then lock.
    19. Once the pivot and lock screws are tightened securely, assembly should look like this.
    20. A view of the installed assembly on the car. Note the route of the boot lid electrical cable, it is critical to match this photo or the lid may be pushed up by the cable if it is routed incorrectly.
    21. A Velcro tie would be a a good addition to secure cable to spring barrel (photo to follow.)
    B7 S4 Cabriolet 6MT, 8P A3 Tip, B5.5 SC/IC V6 5MT

  9. #37
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    Just seen this. Amazing work. WTG Keith!

  10. #38
    4th Gear hu vw's Avatar
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    Quote Originally Posted by keithwbloom View Post
    I sent a kit to Steve in Chicago to install on his B5. He has a Votex spoiler and VW/Audi safety triangle installed on his boot lid, so I have asked him to install with the rev. 1 springs to be sure that they can pull the extra load before I order redesigned spec replacements for all the new kits and the springs sent with original kits.
    With everything you have going on, have you had a chance to determine whether the revised springs are adequate? Thanks again for making this happen.

  11. #39
    SuperCooled30V Moderator keithwbloom's Avatar
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    I have been slacking on this, and it is starting to keep me up at night that I have put it aside for so long. Lemme try to get back on track this week. I do need to move the rest of these units and they aren't going to go anywhere without revised springs!

    Keith
    B7 S4 Cabriolet 6MT, 8P A3 Tip, B5.5 SC/IC V6 5MT

  12. #40
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    Man that is awesome! I always wondered why this wasnt a stock option like it is now on our 2012. I wish I could swing the money to get this for our 2005 but I guess I will just keep saving.

  13. #41
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    Hows Production? I'm still interested on one of these but haven't heard back too much info.

  14. #42
    SuperCooled30V Moderator keithwbloom's Avatar
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    I haven't been attending to this for a while, I still need to workout spring revision with manufacturer. I apologize for the delay. I will circle back to him this week and get a new spring design produced for testing. Those with the kits already will get the testing springs so I have a larger sample set in different conditions. If they work as designed, then I will resume shipping the kits right away.

    B7 S4 Cabriolet 6MT, 8P A3 Tip, B5.5 SC/IC V6 5MT

  15. #43
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    Hi. This is what i have been looking for. How much shipping is to Finland?

  16. #44
    Zef
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    I am interested in one as well if these are still available.

  17. #45
    SuperCooled30V Moderator keithwbloom's Avatar
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    Almost ready to circle back to the spring redesign, then I will be able to supply more of the kits. I have plenty of hardware, just need to get a spring design that will stand up under tension 98% of the time.
    B7 S4 Cabriolet 6MT, 8P A3 Tip, B5.5 SC/IC V6 5MT

  18. #46
    SuperCooled30V Moderator keithwbloom's Avatar
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    Update for everyone —

    Since the Audi OE springs I sourced for prototyping this mod worked well initially (but are too expensive to use in kit,) I have ordered a fresh pair to have tested for pre-load specs before they are stretched out during installation. They should arrive in the next week or so, so I will be getting back on the spring redesign soon after.

    B7 S4 Cabriolet 6MT, 8P A3 Tip, B5.5 SC/IC V6 5MT

  19. #47
    Moderate Moderator Steve in Chicago's Avatar
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  20. #48
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    Can you still purchase a kit?

  21. #49
    4th Gear hu vw's Avatar
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    Quote Originally Posted by keithwbloom View Post
    I like a good project now and again.
    Keith, any progress with the new spring redesign/rates?

  22. #50
    SuperCooled30V Moderator keithwbloom's Avatar
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    Quote Originally Posted by hu vw View Post
    Keith, any progress with the new spring redesign/rates?
    Oh, you got me.

    I suppose I have to get on that first...

    Jammed the arch in my right foot last night. Not going to be ambulatory for a week or so, but spring cleaning is around the corner. I think some neighbors and I are getting a dumpster, and I am going to reclaim my workshop from the clutter of all my Betty/Sabine/Pia projects and set back to work on springs and LED tails. If you saw my workspace, you might understand why I haven't really been innovating anything this winter. Time to clean house!

    B7 S4 Cabriolet 6MT, 8P A3 Tip, B5.5 SC/IC V6 5MT

  23. #51
    Ray
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    Any kits still available?
    keithwbloom likes this.

  24. #52
    SuperCooled30V Moderator keithwbloom's Avatar
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    I have decided to start shipping these again, without the Audi springs, which you will have to source on your own. The springs I had made are not up to snuff, and I don't have enough resources to get them prototyped again, at least not until I sell on a few of these at a discounted price.

    Sooo... I'll sell these hardware only kits for $75, brushed, assembled and shipped USPS to your door. All you need to do is install with a pair of Audi springs, which are $35 each IIRC. The Audi springs work very well.

    Attaching springs to armatures will require two 10mm wrenches. The installation of the kit in your B5/5.5 Passat will require a center punch, an 8mm drill bit, a large flat blade screwdriver, and a 14mm socket wrench.

    B7 S4 Cabriolet 6MT, 8P A3 Tip, B5.5 SC/IC V6 5MT

  25. #53
    Moderate Moderator Steve in Chicago's Avatar
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    Do you have more info on the Audi springs? Part number?

  26. #54
    SuperCooled30V Moderator keithwbloom's Avatar
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    Quote Originally Posted by Steve in Chicago View Post
    Do you have more info on the Audi springs? Part number?
    I'll look them up and post them here. Part number is in my original thread.
    B7 S4 Cabriolet 6MT, 8P A3 Tip, B5.5 SC/IC V6 5MT

  27. #55
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    Is this still active? I am very interested!

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