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Tailgate anti-rattle kit. 900 1993

posted by  Onkel Udo II on  Fri Jan 11 13:43 CST 2013
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last visit: Fri Oct 24 08:50 CST 2014
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So I just installed half the anti-rattle kit on my shiny new wagon. I could not figure out how to use the "lower clips" that were provided. Thanks to Nick I had enough spare trim clips for the bottom.

Two improvements/further repairs I wish to do:

One of the lower tabs for the trim clip is completely missing and one other is cracked. I would like to repair this. First idea that comes to mind is relieve a small amount of the plastic and use fiberglass cloth and resin to form up a new tab. I am open to other suggestions.

Many of the mounts that you screw the aluminum plates to for the upper portion of the kit are is bad shape. If I am to be playing with fiberglass anyway, what do you thing of filling the open portion with mat and resin?

Already 100 million times better than it was and I might be better served by waiting to find a trim panel in better condition as this one even has a small impact hole from (probably) an object rolling around int he cargo area.








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    Tailgate anti-rattle kit. 900 1993

    posted by  dinomartino on  Sun Jan 13 13:32 CST 2013
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    last visit: Fri Oct 24 04:43 CST 2014
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    my 945 came to me with the anti-rattle kit already installed and completely ineffective. I experimented with double-sided tape and adding shims to the anti-rattle add-ons, and none of it lasted more than a few days. My solution is below.






    Placement of the screws up top is key. There's wiring and wiper system stuff that you absolutely do not want to damage. Mine are not elegantly arranged (I'm a bit OCD, so the fact that they are not symmetrically spaced would annoy the crap out of me if I could actually see them while driving) but these were the best placements I could find where there was a reasonable margin of safety that the drill bit would not go rogue and ruin something.

    The big screws are all #12 2" or 2 1/2", the small ones are #10 1 1/2".
    It is important to add a little nickel anti-seize to the stainless screws to reduce the likelihood of galvanic corrosion in the aluminum tailgate.

    It doesn't look very nice, but it is finally quiet.

    John
    --
    1989 245 241K / 1993 945 127K








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      Tailgate anti-rattle kit. 900 1993

      uid 49372's pic
      posted by  740_dan on  Fri Jan 18 14:03 CST 2013
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      last visit: Thu Aug 28 13:10 CST 2014
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      Looks great! Thanks for posting photos, helps a million. Looks tidy too, enough so we would've guessed you're OCD already. :-)
      --
      Try the easy to search Expanded Style FAQ Index **






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        Tailgate anti-rattle kit. 900 1993

        posted by  Onkel Udo II on  Sun Jan 13 15:45 CST 2013
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        I like you lower solution but why did you not do a similar solution on the top.

        What I have in mind is an aluminum L-bracket into the existing slots on the tailgate side with nuts epoxied on the inside of the trim. Drill through the trim and send a machine screw through to the internally epoxied nut.








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          Tailgate anti-rattle kit. 900 1993

          posted by  dinomartino on  Sun Jan 13 15:59 CST 2013
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          I did not put more screws along the top edge because there's less available metal to screw into, plus there's wiring and wiper transmission stuff up there. Also it is much harder to work along the top edge because the glass significantly limits the "angle of attack" with a drill or a screwdriver.

          john
          --
          1989 245 241K / 1993 945 127K








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            Tailgate anti-rattle kit. 900 1993

            posted by  Onkel Udo II on  Fri Jan 18 15:20 CST 2013
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            last visit: Fri Oct 24 08:50 CST 2014
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            I bought some 1/16" AL angle today to star fab'ing brackets when I have time. My hope is to produce a reproducible result with basic had tools that shows no fasteners on the face. We shall see how successful I am.







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