Cat Flap - let’s see.

So today I bought a rear door with the intention of converting it into a cat-flap for my ex-pickup. This could be a long running thread so don’t hold your collective breaths…

As in cat-flap drop down tail-gate and lift up hatch?...

Shippers said:

As in cat-flap drop down tail-gate and lift up hatch?...

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Yep. I have the tailgate which I want to keep, so I’m going to attempt to make s reasonable upper section from this door.

may give you some info or an easy alternative to making it your self https://www.sp-4x4.com/product_p/320652.htm

mystery said:

may give you some info or an easy alternative to making it your self https://www.sp-4x4.com/product_p/320652.htm

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Thanks for the link Mystery. I’ve been looking at the SP one as it does look very well made, plus its a good reference as you suggest.
Id be buying one if it weren’t for the cost (I think I’ve got to shell out for front door skins which I hadn’t planned on).
I wonder if they’d sell me some brackets?
Anyone from SP 4x4 on here?

Cut the donor door in half this evening and offers it up to the hole.
It’s currently about an inch too deep so I’ve got some fettling room.

I also drew up a cat flap hinge in CAD. I’m certainly not going to pay £80 EACH!!! for a bit of bent bar.

Need any pics let me know as I have s2 with rear cat flap.

lynall said:

Need any pics let me know as I have s2 with rear cat flap.

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Hi Lynall. That’s great thanks.
There are some bits of info I’d really appreciate having, but it might involve a tape measure
1. What’s the cross sectional dimensions of the hinge material?
2. What’s the position of the two bolts hole relative to the end of the hinge?
3. What’s the distance down from the top of the door to the bolt holes?
4. What’s the distance from the top of the roof to the hinge pin.
5. If you could stretch to making a side profile tracing of the hinge for me that would be tops

Well, you did offer

Are you going to put the flap on gas struts ?

tottot said:

Are you going to put the flap on gas struts ?

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Yes I think I’ll have to. I think my version will have more glass than a real one and therefore be heavier.

congo181 said:

Hi Lynall. That’s great thanks.
There are some bits of info I’d really appreciate having, but it might involve a tape measure
1. What’s the cross sectional dimensions of the hinge material?
2. What’s the position of the two bolts hole relative to the end of the hinge?
3. What’s the distance down from the top of the door to the bolt holes?
4. What’s the distance from the top of the roof to the hinge pin.
5. If you could stretch to making a side profile tracing of the hinge for me that would be tops

Well, you did offer

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pm me so I dont forget, forgetting is something I excell at!

Stripped the glass and skins from the door top today. It’s a lot lighter now

Ordered a series door repair section from YTM as this will match the profile of the existing door. When it arrives I can cut and weld it to the bottom of the frame.

Made a second pair of anti crush tubes for the near side and silver soldered them into the frame to match the off side.

Got the repair section from YRM this morning (they’re a really good company) and have cut it into the bottom of the frame. I was going to leave the existing rail but in the end it had to come off.
It may be that I need to add a bit in above the new rail.
Glass still fits and it is still square in the hole.

I’ve ended up welding the original cross rail back on. This allows the skin lip to stay the same, as well as giving more strength and height where the latch mechanism will have to mount.
The skins all now fit back properly.

Looking good, are you going to have a seal of some sort along the lower edge of the flap?

tottot said:

Looking good, are you going to have a seal of some sort along the lower edge of the flap?

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My plan was to have a galvanised strip riveted on to the lower face that dropped down over the tailgate. I could possible incorporate a seal into the back of that, but it’d take care of the drops at least.

How will you lock this? I have seen ones with a twist type T handle like on some garage doors, but I liked the upper tailgate handle/latch on the old RRC - though I am not sure of sizes etc as I don't have one anymore, so can't say if they would be suitable.

Dr Strangeglove said:

How will you lock this? I have seen ones with a twist type T handle like on some garage doors, but I liked the upper tailgate handle/latch on the old RRC - though I am not sure of sizes etc as I don't have one anymore, so can't say if they would be suitable.

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It’ll have a T-Handle like on a series. It will operate two horizontal rods that will cam into brackets in the side panels to lock. I’m also hoping to incorporate an internal handle as well.

congo181 said:

It’ll have a T-Handle like on a series. It will operate two horizontal rods that will cam into brackets in the side panels to lock. I’m also hoping to incorporate an internal handle as well.

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I have used the T handle before in various doors and lockers but never used an internal one. I would think you could fit a handle inside too, however these types tend to have a lock in the individual handle so if locked externally you could not exit from inside.

We used a company called Albert Jagger. They do lots of vehicle hardware so it will be worth looking at for some ideas. They were a reasonable price, but we got trade rates. You tend to have to ring or email for prices.