Barn-door To Tailgate Conversion

Hi @dandan89 that’s not right. I know you say yours are not uprated but I had some uprated ones and they were too strong. I have the standard struts and they are fine, you can pull the tailgate down with one hand.
 
Hi @dandan89 that’s not right. I know you say yours are not uprated but I had some uprated ones and they were too strong. I have the standard struts and they are fine, you can pull the tailgate down with one hand.
Hmmm, might be because they are aftermarket. Are yours genuine?
 
Hi guys, firstly I wish I had read more than the first few pages of this thread before I went ahead of the conversion! Due to the peeps having the stress cracks. Everything else has gone smoothly.



So my model is a T6.1 and just wanting to know if I’ve missed something; with the wiring I just hooked up the old barn door loom to the tailgate and everything worked. Only thing I had to do is reverse the polarity going to the unlock solenoid. The boot release from the barn even worked when there wasn’t one on the tailgate loom. So is the T6.1 different because I thought I was going to have to run cables back to the BCM?



Only annoyance left are the LED number plate lights are throwing an error and the I need to change the struts. Hoping as has been discussed the T5 ones will be long enough!



Picture for illustration purposes:

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Hey. I am in the middle of doing this conversion. I bought a new tailgate loom that won't reach but you said your old loom works? I've a t6.1 also and have the tailgate fitted. Jut need to wire it. Have you any pics of the wiring as I dont know what block connectors go where now with the tailgate doors gone..
 
Hey. I am in the middle of doing this conversion. I bought a new tailgate loom that won't reach but you said your old loom works? I've a t6.1 also and have the tailgate fitted. Jut need to wire it. Have you any pics of the wiring as I dont know what block connectors go where now with the tailgate doors gone..
I don’t I’m afraid. Did you get the wiring loom that came from the new tailgate and also have the original wiring loom from the barn doors? I plugged my old loom from the barn doors in and then traced the wire through to where it went, for example the door release; I found which wire was on the other side of connector in the van and cut and tagged it. I did this for all of the wires. I then cut the loom connector off the tailgate loom and used my continuity tester to bell out which wires went where and tagged them. Then it was just a case to then connect them all up and tuck them up above the rear corner D pillar. Quite faffy put easy enough. Someone else might have a better way of doing it but that’s the way I did mine. Also Wago lever connectors are quite good to do a quick connection to test you got it right.

If you find a way of turning the dash error light for the LED number plate lights then let me know!
 
I don’t I’m afraid. Did you get the wiring loom that came from the new tailgate and also have the original wiring loom from the barn doors? I plugged my old loom from the barn doors in and then traced the wire through to where it went, for example the door release; I found which wire was on the other side of connector in the van and cut and tagged it. I did this for all of the wires. I then cut the loom connector off the tailgate loom and used my continuity tester to bell out which wires went where and tagged them. Then it was just a case to then connect them all up and tuck them up above the rear corner D pillar. Quite faffy put easy enough. Someone else might have a better way of doing it but that’s the way I did mine. Also Wago lever connectors are quite good to do a quick connection to test you got it right.

If you find a way of turning the dash error light for the LED number plate lights then let me know!
Thank you. I have the old loom.and new loom but before I go cutting, im just trying to get it working on the old loom which I've just laying across the floor to the tailgate. Did you have to programme anything? I was hoping it would simply work but nothing. Although, I dont have the interior switch if that needs to be present.
 
Thank you. I have the old loom.and new loom but before I go cutting, im just trying to get it working on the old loom which I've just laying across the floor to the tailgate. Did you have to programme anything? I was hoping it would simply work but nothing. Although, I dont have the interior switch if that needs to be present.
Yes I did this first, got everything working with the old loom just plugged in and hanging down. It is handy to have the interior door release but it all still works without it. And no programming needed.
 
I installed a T6 tailgate on a T5 (2004) and ran into a problem with the lights.
Has anyone else had this? They don't sit in place properly, it feels like something is in the way.
There's a gap of about 5-7 mm where they are screwed to the body. You can screw them in by force, but they still stick out a little. The lights are regular, not LED.

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Hi again all quick update on my barn door to tailgate, i have subscribed to obd eleven pro now...there is a large amount of changes possible and seems like a very handy tool !

With a great deal of help finding the right long coding combination from mmi and Pauly I was able to get my tailgate handle and remote locking to work. Yayy

Just the rear wiper to finish off, I have worked out the wiring and have now a working rear washer, just got to connect last 2 wires to get the modified standard stalk to work !
 
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I am nearly finished with my barn door to tailgate conversion and have noticed how badly the adaptor brackets I used have rusted..I won’t mention the company name as I have contacted them to see if I had a bad set or if the finish has come off..I assumed that having the company logo on them meant it was final finish and had no recommendation from them to spray/ powder coat them so i sikaflexed them on.. I would bare it in mind if you are fitting them yourself.
I will update with what they say.
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I am nearly finished with my barn door to tailgate conversion and have noticed how badly the adaptor brackets I used have rusted..I won’t mention the company name as I have contacted them to see if I had a bad set or if the finish has come off..I assumed that having the company logo on them meant it was final finish and had no recommendation from them to spray/ powder coat them so i sikaflexed them on.. I would bare it in mind if you are fitting them yourself.
I will update with what they say.
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They obviously aren’t well coated for what is external use but using stainless steel fasteners just sets up a galvanic reaction, you’d be better of with BZP finish.
 
I wish I had...hindsight is a wonderful thing !

Also I am not getting a great response from the company about how their product is holding up, so I will be looking for another solution!
 
Has @Pewt said, paint them body colour. Get them shot blasted and etch prime them. Order an aerosol of colour and clear coat.
 
Good advice will do that, well not quite will start with some new brackets, paint them and swap them over so the van is not off the road...I haven't removed anything after it has been sika flexed on will they come off ok ? Bit of gentle heating first to soften the glue ?
 
I etched primed mine from new and painted them. Just a light dusting of colour coat to try and stop runs. Not sure on the sika flex, might need a caramel wheel to get the remaining sika flex off your van.
 
Good advice will do that, well not quite will start with some new brackets, paint them and swap them over so the van is not off the road...I haven't removed anything after it has been sika flexed on will they come off ok ? Bit of gentle heating first to soften the glue ?
Use a piece of fishing braided line as a cheese wire to cut through the sikaflex. Use a sawing motion.
Just make sure to wear gloves
 
Thanks both !

Update from c motorsport they advise they are not stainless steel and I should rub them down and paint them to prevent further rust…they have however offered me 10pc off a complete new set !
 
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Finally finished the wiring for the bits that came on the tailgate, now have working exterior handle, locking, heated rear window and as of today working rear washer and wiper.
I wanted to replicate factory wiring connections where possible, but ended up having to splice the final 2 wires into existing which seems a shame after running all the other wires but hey it is working.
Thanks for all the input and comprehensive write ups in this thread.
 
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