DIY Network

Civic SI: Flip-Flop Trunk Conversion From "Tricked Out" episode DTRK-108

	"Flipped Out." In addition to Lamborghini-styled vertical lift doors, we do a conversion on the trunk lid so that it flips down to sit parallel when raised.
	"Curb appeal." Host Andrew Totolos -- with some help from door specialists with Decah Doors -- does some pretty radical things with the lines of this Civic SI.

In this episode, a souped-up Civic gets tricked out even further with Lambo-style vertical-lift doors and a flip-flop trunk. The lift doors are complete. In this second segment, Andrew Totolos dresses up the rear of the car by adding a flip-flop trunk.

Materials used in this project:

Panel-removal tool
Wire ties
Marking Crayon
Marker
Hammer
Center punch
Bench vise
Two 4" strap hinges
Two bolt latches
12 flat washers
12 self-tapping screws
Ratchet
Drill and #2 Phillips driver bit
Other various drill bits

Important: Included below are the steps in this automotive procedure as shown in the episode. These steps are general guidelines. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of repair-kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

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	Figure A
	Figure B

Flip-Flop Trunk Conversion

The "Lambo-styled" vertical-lift doors (figure A) are without doubt an upgrade that's certain to turn heads. But we decided to dial this upgrade up a notch. With the vertical-lift doors installed and working properly, the next phase in tricking out our Civic SI is the trunk and a specially installed "flip kit."

To complement the modified lines that come with the vertical doors, we convert the ordinary trunk-lid -- which opens at the standard 90-degree angle (figure B) -- into one with a custom flip so that, when the trunk is opened, the lid remains flat. This particular conversion works especially well with Civics and other cars with similar hinge systems. Trunks with other types of hinges or lift mechanisms may prove more complicated.

DIY Difficulty Rating for this Project: This job is a medium difficulty project, and will generally require two people. We gave it a difficulty rating of 3 on a 5-point intermediate-level scale. Experienced gear-heads should have no problem with these upgrades.

Installing the Hinges

• To begin the conversion, disconnect the wiring harness and trunk release that runs along the bracket. A panel tool will help with this operation (figure C)

• Unplug the harness at the taillights on both sides (figure D).

• Disconnect the remote trunk release cable and the wiring that operates the spoiler-mounted brake light.

• Slide all the wires out of the holes in the trunk and set them aside.

  Figure C

  Figure D

  
  

• Before you remove the trunk lid, mark the trunk at the end of the factory brackets with a marker to provide a reference point for installing the new hinges (figure E).

• Have a helper keep a solid grip on the trunk lid as you remove the bolts (figure F).

• Carefully take the lid completely off and lay it aside.

  Figure E

  Figure F

  
  

• You'll have to bend the hinge to match the contour of the trunk frame. Set the hinge in place on the factory bracket with the barrel side down. Mark the depth of the bracket on the bottom of the trunk-side hinge leaf (figure G).

• Bend the hinge at the mark using a hammer and a vise (figure H).

  Figure G

  Figure H

  
  

• Using the factory bracket marks you made previously, position the new hinge with the barrel side up, and mark the trunk frame at each hole (figure I).

• Use a center punch to dimple the frame at each mark. Attach the hinge to the trunk lid with the self-tapping screws provided (figure J).

  Figure I

  Figure J

  
  

• Next, set the trunk lid back onto the brackets in the flipped position and mark the backside of the stock brackets at each mounting hole (figure K).

• Set aside the lid once more while you punch the marks.

• Pre-drill the holes with a drill and the self-tapping screws (figure L).

  Figure K

  Figure L

  
  

• Set the lid back in place (figure M) and attach the bracket-side hinge with a screwdriver so you don't strip anything (figure N).

Figure M

Figure N

Flip-Flop Trunk Conversion: Installing the Latches

The new flip-top hinges are now installed. To finish off the trunk-lid conversion, we need to add a couple of barrel latches so that the trunk can operate normally. Here's how we did it:

• Use a crayon to mark the end of the latch bolt. Then hold the latch in place to transfer the mark to the bracket (figure O).

• Mark the center of the crayon transfer with a permanent marker. Then dimple the mark with a center punch to keep the drill-bit from wandering.

• Use a cordless drill to drill the mounting holes (figure P). Start with an eighth-inch pilot hole, and enlarge the hole as necessary to fit the latch bolt.

  Figure O

  Figure P

  
  

• Place the latch into the hole and mark where the screws will go (figure Q).

• Then punch a guide hole and attach the latches with self-tapping screws (figure R), being careful not to strip the holes.

• The latches should hold the trunk lid securely in its original position and lock tight enough to prevent any rattles.

• Now all you need to do is reattach the wiring, and the flip-flop trunk project is complete.

  Figure Q

  Figure R

  
  

  	The "flip-flop" trunk is specially hinged so that, when opened, the lid remains parallel to the body rather than at the standard 90-degree angle.
  	Anybody need a lift? The Honda Civic SI with "Lambo-style" vertical-lift doors.

$1699 "Lambo" door-kit
$8 Hinges and latches for "Flip-Flop" trunk

Total = $1707

RESOURCES :

Sport Compact Bolt-On Performance Guide: Import Cars (Sport Compact Bolt-On Performance Guides)
Author: Joe Pettitt
Order this book from Amazon.com.
Voyageur Press (October 2000)
ISBN: 1884089526

Honda & Acura Performance Handbook (Performance Handbooks)
Author: Mike Ancas
Order this title from Amazon.com.
June, 1999
Publisher: Motorbooks International
ISBN: 0760306699

Decah, LLC
Website: www.decah.net

Racing Innovations, Inc.
Website: www.racinginnovations.com

Bend-Pak
Website: www.bendpak.com

GUESTS :

Kevin Rochon and Ernst "Eclipse" Goldman Jr.
Decah, LLC
Livingston, NJ
888-551-1154
Website: www.decah.net