My poplock tailgate creation - Dodge Cummins Diesel Forum
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post #1 of 2 (permalink) Old 04-11-2019, 03:38 PM Thread Starter
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My poplock tailgate creation

I like the idea of a locking tailgate and I got a rollup Tyger 1 toneau cover, so now its worth it to me.
I bought a pair of lock actuators off amazon for $8, they work.
I also bought a key locking tailgate handle, so its going to have 2 locks on the tailgate.

I had to create a functional design and I did, but its not finished yet. I did this album work today. I made spacers out of waterproof laminate sample floor pieces form H Depot. They allow the parts to fit properly attached to the inner tailgate stamped metal. I cut and fit and then glued in with hotglue. The bent hinge requires a double layer, 1/4" thick glued to the inner sheet metal to make a flat surface, then a 3/8" thick piece to space the hinge so it aligns with the door lock mechanism. The actuator just needs 2 pieces glued to the inner sheet metal.

I plan to wire in so the tailgate locks and unlocks with the passenger doors, not the driver door.

I bent a door hinge to shape, then I had some spring steel rod from an old trunk lid lift spring and used that for the locking pin.
The actuators come with a rod attachment block. I enlarge the end with a drill to fit my locking pin rod diameter and JB welded it onto the locking pin rod. That rod is slightly over 1/4" diameter so I had to drill out the hinge pin to fit. Still need 2 small bolts to finish attaching the bent hinge.
Whats left is figuring out the linkage from actuator to the locking pin. And the wiring. It is just 2 wires, polarity reversals make it move in or out.

I dont see why it wont work. One video I saw had used 2 relays to offload the power drain of this extra actuator. I dont know if thats needed. I dont know if the computer monitors power usage. Album has all the pics I took.

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post #2 of 2 (permalink) Old 04-12-2019, 05:41 PM Thread Starter
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I got it all working. My total cost was only the $8 for actuators. For wire I used an old vacuum cord 17 gauge.
I split the wire at the tailgate so the wire can be undone when tailgate is removed.

I had a hard time figuring out the wires. Took entire passenger back door apart. I found there are 4 wires going into the lock mechanism in the door. The 2 wires that actually move the lock motor up and down in the right rear door of a 2005 ram 3500 are colored solid green and tan/orange strip. The other 2 wires (purple/white stripe, green black stripe), might be for the courtesy light for the truck to know if a door is not shut.
These colors change after the body plug behind the center door column. Light green becomes light green with blue stripe, and Tan/orange stripe becomes Violet with blue stripe. And that carries all the way to the body plug behind the passenger kick panel.

I drilled a 1/2 inch hole, put in a rubber wire protector and sealed the wire so water cant get into the cab.
I tied the wire up all along the passenger side frame rail back to the spare tire.
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