Ibiza Mk4 Custom Gas Bonnet Lifters/Struts - Finally Finished!

Pabs

Active Member
May 3, 2004
5,936
4
Basingstoke
Been there and done that - didn't get anything close to the spec I wanted. But if you were to modify my designs slightly - you could easily get away with one around 10-20mm longer (keep bonnet opening at same OEM angle - mine is slightly lower) but force is the issue - most I found were weaker than my required calculations.

That said - I didn't need the full 400N each anyway...300N a piece might be ok, but it'll be more work if they are too weak.
 

Damoegan

Sir Bob,a geordy legend..
Oct 15, 2007
8,993
3
Newcastle
If I do get something from a scrappy and it dont work then I aint realy going to lose anything. Then I'll get the ones you have :)

Could you tell me the distance from the threaded holt to the 8mm (closest) bolt hole please?
 

Pabs

Active Member
May 3, 2004
5,936
4
Basingstoke
shorter struts would need bigger forces, and just don't seem to be available out there. You'd then need a bigger diameter strut which probably wouldn't fit in the grove in the underside of the bonnet.

Damo - can't give measurements at the moment mate - but as said will try and get my diagram scanned in.
 

Pabs

Active Member
May 3, 2004
5,936
4
Basingstoke
See post #2 for dimensions diagram mate - just nipped out to garage to find where I left it. lol.

Please note that some dimensions changed according to diagram - rather than angled section, it was cut off square (top) and the width is not 30mm - I had to use a mill and trim off approx 2mm from the inside edge (closest to engine) of the bracket as it very slightly fouled on the bonnet hinge which has a lip.

The m6 bolt hole for the ball-head screw is tapped and "locktited" - the 2 M8 holes (and additional 3rd M8 hole in N/S bracket) are not tapped.
 

Pabs

Active Member
May 3, 2004
5,936
4
Basingstoke
Oh - and at this point in time, I want to claim the award of "first ever hydraulic bonnet lifter for the mk4", but if that one is already taken - then add to the end "that doesn't require drilling/modifications"

:p:p:p
 

Pabs

Active Member
May 3, 2004
5,936
4
Basingstoke
Nice one mate. I'll knock up a few brackets when I'm back to work on Thursday :thumbup:

See, had you done this months ago before I got a mk4, you could have claimed the title ;)
But alas, I beat you to it - so :p hehe


I also accept no responsibility for damage to your car(s) or yourself if you decide to copy my ideas! :D
 

Pabs

Active Member
May 3, 2004
5,936
4
Basingstoke
:p

Good luck with the hunt at the scrappies - let me know how you get on!

Oh, and be warned about the bonnet hinge bolts - might be worth getting some a bit longer - suggest extra 3-4mm in length if possible. I was concerned about c*cking up the thread on one of my bolts, but managed to get it to catch in the end.
 

Pabs

Active Member
May 3, 2004
5,936
4
Basingstoke
sweet!
I've got some more stainless bolts here, but they're too long so I'd need to cut them down.
Plus they didn't really look OEM, so I didn't want to use them :p

Picky, huh? haha
 

Pabs

Active Member
May 3, 2004
5,936
4
Basingstoke
thanks folks - if Damo gets the design replicated and working, no doubt he'll sell a few. :) All the hard work is done now - all you need to do is copy it!

It is one of those cost-cutting exercises - I don't think the Polo's came with them either.

Just a word of warning though - if you do get fixed force struts - you could end up bending your bonnet or breaking the hinges if they are too strong, or, from the other view - too weak and you'll have a bonnet wrapped around your head while you're working under it!
 

RUM4MO

Active Member
Jun 4, 2008
7,784
983
South Scotland
thanks folks - if Damo gets the design replicated and working, no doubt he'll sell a few. :) All the hard work is done now - all you need to do is copy it!

It is one of those cost-cutting exercises - I don't think the Polo's came with them either.


Well the original 9N Polos came with them - I've a hunch that they may have been dumped by the time the face-lifted 9N3's came along - probably to save money.
 
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