Cat Flap - let’s see.

congo181 · May 21, 2022

Dr Strangeglove said:
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.

I’ll look them up - thanks.
This is what I’m looking at at the moment.

Dr Strangeglove · May 21, 2022

congo181 said:
I’ll look them up - thanks.
This is what I’m looking at at the moment.
View attachment 265501

That's the stuff they do and many associated bits too.

congo181 · May 21, 2022

Dr Strangeglove said:
That's the stuff they do and many associated bits too.

They have a great inventory. Thanks for the tip. I think I’ll be going to them for the lock mechanism rather than knocking something up myself. Cheers.

congo181 · Jun 8, 2022

Got the lock mechanism from Albert Jagger this morning so did some work on the cat flap.
Made and welded a bracket for the lock, and drilled all the holes for the handle.
Added the rod supports at either side if the frame.
Random fasteners at the moment and the handle fixing bolts need trimming to length but it works in principle.
Next stop, hinges.

Dr Strangeglove · Jun 8, 2022

congo181 said:
Got the lock mechanism from Albert Jagger this morning so did some work on the cat flap.
Made and welded a bracket for the lock, and drilled all the holes for the handle.
Added the rod supports at either side if the frame.
Random fasteners at the moment and the handle fixing bolts need trimming to length but it works in principle.
Next stop, hinges.
View attachment 266750 View attachment 266751 View attachment 266752 View attachment 266753

Looking good. Remember Albert Jagger also do hinges and rubber seals. Unfortunately the seal comes in 50m coils I think, but there are lots of profiles on their site. Sometimes you can find the same profile on ebay.

Dr Strangeglove · Jun 8, 2022

Also try to get a look at a range rover tailgate to have a look at the seals on that.

congo181 · Jun 18, 2022

Made a hinge bracket.

congo181 · Jun 20, 2022

Finished both the upper hinges for ‘project cat-flap’. They were quite tricky to make (for me) so I’ve posted some pics of how I did it.
The original hinges are made from 1.25” x 0.25” but it’s much easier to get hold of 30mm x 6mm so this is what I’ve based these around.

congo181 · Jul 2, 2022

Bit of a wait while my mate bent the hinge
arms for me, but now they’re back and hung on the roof. Good news is, they lift to 90° and clear the roof. So now to adapt the arms width to meet the window sides.

congo181 · Jul 3, 2022

Some fettling, and I’ve got an offset to the hinges arms that line up with the uprights in the donor door.
The door swings open ok, but currently the top ally skin fouls the underside of the roof gutter so some more fiddling is required.
Progress though. It now looks like it may even be a success.

mystery · Jul 3, 2022

Looking good

meego · Jul 3, 2022

I’m enjoying this. Some great skills and off the cuff design going on. Do you think the bent hinges might be a bit springy when the weight of the glass is added in though ??
Edit
Scratch that thought. I forgot that you are putting a gas strut/s in and this should support it eh ?

Disco1BFG · Jul 3, 2022

Excellent work. Good to see

congo181 · Jul 3, 2022

meego said:
I’m enjoying this. Some great skills and off the cuff design going on. Do you think the bent hinges might be a bit springy when the weight of the glass is added in though ??
Edit
Scratch that thought. I forgot that you are putting a gas strut/s in and this should support it eh ?

Hi Meego and thanks for your comments.
I had considered the weight, especially as they’re only mild steel for the hinges. As you say, I’m thinking that the gas struts will hold the weight when it’s open, and the bolts the same when closed. Fingers crossed

congo181 · Jul 3, 2022

Disco1BFG said:
Excellent work. Good to see

Thanks Disco

Al2O3 · Jul 3, 2022

Just found this thread. Cracking fabrication

congo181 · Jul 4, 2022

Been working on the latching mechanism this morning. Fabricated a fixture that receives the locking bolt, that mimics the original series design. Seems to work ok, but needs some movement built in for adjustment. Got to make the opposing one now it works.

congo181 · Jul 4, 2022

Two now made with slots to allow closure to be adjusted.

mick the builder · Jul 4, 2022

Great job.

congo181 · Jul 4, 2022

I’m getting some interference between the top of the door frame and the bottom of the gutter as the door is opened, but only on the off-side. My tiny brain cannot work out the required adjustment. I could just lower the door (when closed) but that would adversely affect the shut lines.
Anyone good at adjusting these type of hinged doors?

Cat Flap - let’s see.

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