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Aluminum engine hatch upgrade 205v

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  • Aluminum engine hatch upgrade 205v

    Been wanting to upgrade my engine hatch cover for quite some time now on my 205v. My current one is mashing on my throttle body wire harness everytime someone walks over it. I bought a sheet of 36”x45”x1/4” plate aluminum and 2 - 8ft sticks of 2” square by 1/8” thick tubing today. Will drop off the material in the next few days at my metal shop guys place to get the ball rolling. Only concern so far is the weight. Uncut material weighed in at 56 pounds. Hopefully will be able to get the hatch built at around 45 pounds after all the cuts are made.
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  • #2
    Made a template piece today. Turned out a little to big. Will shave more down so it does not rub against the vinyl.
    Attached Files

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    • #3
      Did my final template with another piece of sheetmetal and it’s a perfect fit. Here is a sketch of the what I’m building for anyone else that is interested. I left the ends open on the frame because I want to use locknuts and bolts on the existing hinges and want access to them down the road. I did not want to seal them because I have not had good luck with rivet nuts in the past and this hatch is going to be a heavy pig. Will seal the openings with plastic caps that I found on eBay. I will also let my welder decide if the frame needs a center brace. From what I can tell so far it’s not necessary because the 1/4” plate does not flex. Should have everything back by next Friday.
      gwozhog
      MC Devotee
      Last edited by gwozhog; 10-23-2019, 11:09 PM.

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      • #4
        Frame
        Attached Files

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        • #5
          Top plate
          Attached Files
          gwozhog
          MC Devotee
          Last edited by gwozhog; 10-24-2019, 11:44 AM.

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          • #6
            Alright got my engine hatch back today from my metal guy. He delivered big time. Perfect fit. If anyone else is interested in getting one made for there 205v shoot me a pm. Now I need to paint it and get some gatorstep made for it.
            Attached Files

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            • #7
              This piece weighs exactly 43 pounds. Will need to beef up the shocks. Attach a safety rod too.
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              • #8
                Looks great. Where you close to the 45lbs total weight?

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                • #9
                  This is awesome!

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                  • #10
                    Originally posted by mmskiboat View Post
                    Looks great. Where you close to the 45lbs total weight?
                    43 pounds exactly

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                    • #11
                      Looks good. Keep the pics and updates coming.
                      2005 X2, Viper Red, MCX, Acme 1285, PPass, rear 750 sacs, KBS, IBS, Bennett Wake Plate
                      (previous) 2001 X5, 1991 TriStar 190

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                      • #12
                        Well im still waiting on my Gatorstep but I atleast got the artwork back from them. Decided to drop the deck off and get it powder coated too.
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                        • #13
                          Gatorstep arrived and I still need to paint. It’s been to cold and rainy lately too. Hopefully have this installed permanent in the next few weeks
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                          • #14
                            Originally posted by gwozhog View Post
                            Gatorstep arrived and I still need to paint. It’s been to cold and rainy lately too. Hopefully have this installed permanent in the next few weeks
                            Looks great! Looking forward to seeing the finished pics.

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                            • #15
                              That's a great idea, nice work! Mine doesn't have any issues, but I hate how it isn't flat when I step on it do the the plastic insert under the foam. Please post finished pics when you get it done.

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