Long awaited How to:Flip Flop Trunk

[Shane5425]

I know, I have been puttin it off for a while now. I have been busy with my trunk setup. Now that i have ran out of resin, i have time to do this now.
excuse my pictures, i still ahve some clean up work to do and painting, but here is how to do it..



Materials

Large Gate hinge
Self taping bolts
2500 psi epoxy
square holy tubing
4 push pins
4 carrige bolts with washers and nuts
4 short bolts with washers and nuts

Tools
Friend
Die grinder
Common shop tools(wrenches, ratchets sockets, ect.. )
Cordless Drill with drill bit assortment..


Ok here it goes

Step One: remove the trunk from the car(get help with friend)
Step Two: Take the hinge and line it up onthe trunk support bars where the factory bolts go threw. Trace then with a pencil and Drill them out to size.
Step Three: Bolt the trunk up with the hinge on the outside , and make note at where you have to bend the hinge to get the other side of the hinge to sit flat on the trunk itself. ending results you should get this .

http://www.msprotege.com/members/shaneMazda2000P/Picture%20003.jpg

Step Four: Remove the hinges and trunk, Bend the hinge at the places you marked it needed to be bent.

Step Five: Repeat steps 3 and 4 until the hings sits flush on each surface.

Step Six: with the hinge bolted to the trunk from the bar, take the other side of the hinge(part that is flush with the trunk lide itself) and mark holes. Drill out to the size bolt you have.

Step seven: Bolt the hinge to the newly drilled holes.

Step eight: Remove the trunk lid , with the carrage bolts bolt the hinge to the trunk arms, Tigheten untile the carrage bolts crush the arms until they are flat with the rest of the metal*** I CANNOT STRESS THIS ENOUGH YOU MUST DO THIS IN ORDER FOR IT TO SIT FLUSH SO U HAVE NO WATER LEAKS.

With all this tightend up ur trunk will Flip Flop Now onto the locking system i made that works better than the simple slide bolts found in ebay setups.

Step One: Get someone to hold the trunk in the up possition. cut a 4 to 5 inch piece of the holey square tubing.

Step Two: With some self taping screws bolt it in place.

Step Three: From the side Draw some marks where the push pins will go threw the tubeing into the trunk arm.

Step four: Drill the arms on the spots marked , and waddle outthe tubing wholes so the pins can slide in freely.

Step five: Check and make sure everything works and seals properly. Then remove the tubing and put some of the epoxi on the back of it and put it back in place , bolted up and pins locked in place, let the epoxy set and dry.

And you are just about done, Clean up the any cuts and bends you made.. looks crude without being painted so i would advise painting it , i plan on it..

i have 12 pictures to referance off of

http://www.msprotege.com/members/shaneMazda2000P/Picture%20001.jpg
http://www.msprotege.com/members/shaneMazda2000P/Picture%20002.jpg
http://www.msprotege.com/members/shaneMazda2000P/Picture%20004.jpg
http://www.msprotege.com/members/shaneMazda2000P/Picture%20005.jpg
http://www.msprotege.com/members/shaneMazda2000P/Picture%20006.jpg
http://www.msprotege.com/members/shaneMazda2000P/Picture%20007.jpg
http://www.msprotege.com/members/shaneMazda2000P/Picture%20008.jpg
http://www.msprotege.com/members/shaneMazda2000P/Picture%20009.jpg
http://www.msprotege.com/members/shaneMazda2000P/Picture%20010.jpg
http://www.msprotege.com/members/shaneMazda2000P/Picture%20011.jpg
http://www.msprotege.com/members/shaneMazda2000P/Picture%20012.jpg

end results, here ya go peeps.. http://memimage.cardomain.net/member_images/6/web/402000-402999/402321_118_full.jpg

[SIBalla23]

How much did it cost you to do all this?

[Shane5425]

20 to 35 dollars depending on where you get ur supplies from..

[SIBalla23]

Not to bad for a sick mod if done right. I forgot to ask before, how long was the install? Also how hard was it to do on a scale of 1-10, 1 being very easy to 10 being a pain in the ass?

[JCell]

is there any trouble closing the trunk now?

[Shane5425]

scale 1 to 10 a 5 trunk closes like normal if done correctly..

[JCell]

^^ what do u mean if done correctly?...

[Shane5425]

^^ what do u mean if done correctly?...

if you follow my steps u wil do it correctly, what i am sayin is in referance to the other ways people have said to do it, by puttin th ehinge in between the trunk and arm, but in min i put it on the bottom of the arm so it will sit flush and be able to close like stock and not 2 to 3 mm higher.. small , but it will make a differance..

[Shane5425]

any suggestions or improvements to the design are welcome, i want it to be the best solution for a flip flop trunk lid for the protege.. and if it is worthy , can a mod put it in the how to section?

[sam1]

i tried this a couple months ago and didnt like it. i loved how it looked when it opened, but i didnt like having to lock it in place to close it and unlock it to fold it down. ive been playing with some ideas to make it shut and open without the locks, but none of them have worked yet.

[Rism]

ghetto fabulous

[peepsalot]

How about a pic of the end result. I can't even tell what is going on here, the pics are too close up.

[Shane5425]

How about a pic of the end result. I can't even tell what is going on here, the pics are too close up.fixed it, look at first post

[J dragon]

(google) <---wtf new smileys everyday, anyways..this should definately be in the how-to section, good Write up Shane

[Shane5425]

(google) <---wtf new smileys everyday, anyways..this should definately be in the how-to section, good Write up Shane

who is the mod to switch ti to that section?

[nadim]

well i just did mine tonight but used a diferent position for the hings and it is working goood just need to get some bigger bolts and i'am done tha trunk closes normale didn't checked yet for a leak but will do that tomorow and tell u guys here are some pics ill take some clearly one tomorow..and it is a really nice mode and also cheap well the hings cost me like 15 box and welll just some bolts like othe 5 and ur done .
1.
1-With the trunk open mark the trunk lid at the top of the stock brackets by either scratching the paint or using a colored marker.<?xml:namespace prefix = o ns = "urn:schemas-microsoft-com:office:office" /><o:p></o:p>
<o:p> </o:p>

2. Lay towels along the side of your car, and with a friend remove the trunk lid by unbolting the stock 4 bolts (Hondas 10mm other cars may be different). Do not remove the stock brackets, only the trunk lid. Either cut or disassemble the zipties for the cables on the side of the hinge to fully remove the trunk.<o:p></o:p>

<o:p> </o:p>

3. With the lid off of the stock hinges, lay the new hinge on the lid for marking. The new hinge should be flat side down, with the circular part of the new hinge facing you, not the lid. Line up the top of the lower bracket to the marked line on the lid. Flatten the hinge on the lid and mark the lid for drilling. Using the screws that came with the brackets, attach hinge to the trunk lid by hand, not a drill. Repeat this step with the other side. Once both hinges are on, you are ready to reattach the trunk lid.<o:p></o:p>

<o:p> </o:p>

4. With help, lift the trunk lid to stock brackets. With the lid flipped down like it will be when you’re finished, line up the new hinge on the stock hinge for marking. Mark the holes on the stock hinges to pre-drill your new holes. Put lid back on the floor, and drill out the holes. When the new holes are drilled, attach new hinges to the stock ones using the screws. As said before, screw in the screws by hand, not a drill. Once all screws are in place, the trunk lid should be in the flipped down position. The lid should rest on the car in a flattened position. If it is flipped down too much, you may need to bend the upper hinge down to allow the lid to rest against the car.<o:p></o:p>

<o:p> </o:p>

5. Lift lid to the stock normal position and reattach stock bolts to hold lid up. Connect the first latch about 2 inches from the bottom of the trunk lid. Repeat for the other side. Be sure they are mounted on the inside of the stock brackets, and are flat and not angled up or down.<o:p></o:p>

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6. Mark a spot on the stock brackets to drill to allow the latch to lock. Be sure the latch will lock tightly and there is no play. Repeat on the other side.<o:p></o:p>

<o:p> </o:p>

7. If it doesn’t latch tightly you may have to take in and out the stock bottom bolts each time you want to fold down your trunk lid. (This may work better if your not going to fold it down all the time).<o:p></o:p>

[Shane5425]

check for a water leak now, itried that the first time and had a water leak..

[nadim]

well i tried to see if ther is a leaking nad thanks god no looking man,u just have to make it fit well and stay as like factory to be good sealed.

[mazdaon20s]

wow those trunks look real good how are they working now i wonder if that will work on the mazdaspeed 6 should huh any real problems that you guys have had i had 4 12s in my protege and i would of loved to open the trunk like that

[steve_protege]

How hard is this to do? Im on the fence as to whether or not I want to do this. But every time I see a picture of someone who has done this, I so wanna do it to mine. How long did this take to get done? Have any problems with it yet?

[nadim]

well it is not so hard man u just have to make and keep the best fit as factory and u won't have any trouble,and believe me it is a piece of cake u just need help from a friend to help holding the trunk and make the work easy.but believe me it is worth it people just keep on looking and asking how u done it !! ill try to post new pics a more clear so u can see how is it done...




How hard is this to do? Im on the fence as to whether or not I want to do this. But every time I see a picture of someone who has done this, I so wanna do it to mine. How long did this take to get done? Have any problems with it yet?