Custom 2" inch hitch installed - advice needed

[SFHGolfTDI]

UPDATE: You can see how things turned out and some more pics in Post 19: http://forums.tdiclub.com/showpost.php?p=4828446&postcount=19

Original post with the issue I was having and some fabrication pics:

Yesterday I went to a local hitch welder and had them custom fabricate a hitch for me based on some of the designs on this site using the eurohitch mounting points in the frame rails. They were reluctant at first because they don't generally like customers coming in with special design requests, but said if I took all the measurements and told them where I wanted the receiver, they would do it, but take no responsibility if it doesn't turn out exactly how I wanted it.

I was working with some pretty tight measurements, but did my best with it. I figured out that the 6" receiver would not need to be cut IF it could be flush against the car behind the spare wheel compartment. That would put the hitch pin hole barely behind the bumper cover where I would access it from underneath. Unfortunately, I didn't realize they were also adding a supporting plate behind the receiver, which meant another 1/4-3/8 inch, which meant that my hitch hole sits like this:

There is enough flex in the bumper that I could probably force whatever I wanted into the hole, but it is tight and will be hard to get a wrench in there for a locking pin or my bike carrier which attaches with a 19mm head 1/4" bolt.

If you were in my position, would you:
1) Cut the bumper more to allow for better access?
2) Drill a smaller hole on the outside of the bumper for my bike rack (primary use)?

 

[SFHGolfTDI]

One more pic of the final product without the cover:

 

[hskrdu]

I can't offer any advice, but I think it looks great. I love all these alternatives to the Bosal/Westy hitches.

 

[SFHGolfTDI]

Thanks, Steve! I'm trying to get over being frustrated that it didn't turn out exactly as I wanted. I've been planning it and measuring for a while, and it came down to an unforeseen 1/4 or 3/8" to throw things off a bit. At this point, I'm still debating which of the top two options to pursue. I'm leaning toward cutting the bumper more on both sides.

 

[hskrdu]

You're really only cutting the black part? In the front that's the valence, maybe on the rear it's the rear valence? I wouldn't worry too much about cutting that part. You could always pull one off a salvage bumper if you later want/need a different one.

I read your text, and looked closely at the pix. Is the issue that you need to attach tow chains, and the space is too tight? Or that the space is too tight for your hitch mounted bike rack?

 

[SFHGolfTDI]

You're really only cutting the black part? In the front that's the valence, maybe on the rear it's the rear valence? I wouldn't worry too much about cutting that part. You could always pull one off a salvage bumper if you later want/need a different one.

I read your text, and looked closely at the pix. Is the issue that you need to attach tow chains, and the space is too tight? Or that the space is too tight for your hitch mounted bike rack?

Hey Steve, yes only the black part. The issue is that the rear valence goes right over the hole where the hitch pin / bike rack bolt goes through (plenty of room underneath to attache chains, etc.). But to get a pin in the hole, I either need to flex the valence out of the way (if it is possible to flex that far), cut more of it out to make room for the hole, or drill a new hole behind the valence away from the car.

I liked the clean look of having it cut close to the hitch, but if it's not practical then no use in having a hitch! So I'll probably just cut more of it away. As you said, it's a fairly cheap part and easy to find if I ditch the hitch later or get a euro hitch.

 

[hskrdu]

Ok, I see it now. I actually couldn't make out the darker area for the hole (not that I have a Retina screen or anything) until you pointed it out. Now I can see it most clearly in the 4th pic where the light is passing through it. So, your hitch rack gets inserted into the receiver, and the pin locks it in place? How often will you take the hitch on and off?

 

[SFHGolfTDI]

Right, the hole location is the problem. Couldn't be worse, actually. It was what I was trying to avoid in measuring and remeasuring things for months. But when they went to weld things up, 1/4" piece of steel I wasn't aware of until that moment threw everything off. He asked me about it and I should have probably asked them to cut the receiver down 1/2" right then to ensure I didn't have a problem. Oh well

I'd probably take the bike rack (if that's what you mean) on and off fairly frequently since it goes on my wife's Jeep too. So it would be nice if the bolt holding it through that hole was not a hassle (need to ratchet or wrench it on, and it is not small, 19mm head).

 

[hskrdu]

Yes, bike rack, sorry. If it goes on and off often, I think a little more valence removed wouldn't be noticeable.

Can you open the hatch with the rack in place? I've seen some that swing, and some that drop, but I use a hatch mounted version, so I haven't really checked the others out. The hatch mount is great on the Jetta, since it opens and closes with the trunk. On my Golf, however, the clearance isn't enough to allow that to happen. I've been looking at getting a used Whispbar.

 

[SFHGolfTDI]

I have the Thule T2 platform style rack. It folds down and I'm pretty sure the hatch will open with bikes on it but I haven't put it in yet.

I also have the oem golf hatch mount now listed for sale. It's nice but the bikes ride pretty high. Opening a little was possible but heavy.

 

[hskrdu]

Cool. I'd like to use the hatch mount on the Jetta, but will look at other options for the Golf. I'll have to check out the T2.

I like those Mavic wheels!

 

[redbarron55]

Why not just use a pin for the connection. The bolt is no safer.

http://www.northerntool.com/images/product/2000x2000/578/578213_2000x2000.jpg

 

[SFHGolfTDI]

Why not just use a pin for the connection. The bolt is no safer.

A pin would not be compatible with my bike rack, which has a threaded weldnut in the shank to thread onto the bolt for anti-rattle purposes.

The bolt is this part: https://www.etrailer.com/Accessories-and-Parts/Thule/853-5917.html

 

[vandermic07]

you could have mounted it behind the license plate and made a flip up bracket. i can access everything through a hole a little smaller than the license plate. and it is hidden so when your hitch decides to rust up, you wont see it.
Looks good and professional.

 

[SFHGolfTDI]

Cool. I'd like to use the hatch mount on the Jetta, but will look at other options for the Golf. I'll have to check out the T2.

I like those Mavic wheels!

Definitely check out the T2. It is as good as it gets for US bike racks, short of a Kuat. But you'll need a hitch for either.

If I had to do over, and I didn't already have the Thule rack, I'd have gone with a euro hitch and euro ball mounted bike rack. They get all the goodies over there!

My poor bike needs some TLC and riding. Have done very little of that lately between toddler and pace of life lately. Instead, I've been spending too much time on car projects!

 

[SFHGolfTDI]

you could have mounted it behind the license plate and made a flip up bracket. i can access everything through a hole a little smaller than the license plate. and it is hidden so when your hitch decides to rust up, you wont see it.
Looks good and professional.

Yeah, I've seen that on the forum and considered that idea when figuring out which design I wanted to go with. But I don't mind showing off a hitch. Also, this is design is completely reversible with a new bottom valence and no hole in the painted bumper cover (even if behind a license plate). I can sell hitch and valence together and go with a euro hitch if I ever want to later. Replacing the rear valence is pretty cheap used or new.

 

[KCTDI]

Possible to drill the pin hole farther forward?
Perhaps even in front of the vertical gusset shown in your seventh picture?
I built one similar for my '03 wagon, ended up trimming my valance at an angle, wider at the bottom because of the way the valance is shaped.

 

[SFHGolfTDI]

Possible to drill the pin hole farther forward?
Perhaps even in front of the vertical gusset shown in your seventh picture?
I built one similar for my '03 wagon, ended up trimming my valance at an angle, wider at the bottom because of the way the valance is shaped.

Would love to see pics of yours.
I've thought about putting another hole further forward, and it wouldn't need to be as big for my bike rack bolt, which is much smaller than a standard 5/8 pin. But then I still have a problem if I want to tow. Something like this:

 

[SFHGolfTDI]

Update, how things turned out

So, after dabbling with the idea of having the receiver cut down and rewelded, I opted to take the path of least resistance and cut out the bottom valence a bit further to accommodate. You can see where I put a coat of matte black paint behind the receiver so there isn't silver showing through the valence cutout. Also, since I have a toddler, I wanted a little bit more steel between the car behind me and my car, so I went back to the weld shop and had them weld up two posts to mount my bumper support (using the bolts, so it can be returned to stock and hitch sold). It cost a bit more, but I thought it was worth it:
https://flic.kr/p/uSfiZB
https://flic.kr/p/uRZo2D

After having originally cut the valence a little bit, I realized I still had to cut a little more to accommodate hitch pins or bolts comfortably. The first pic is my first attempt, bottom pic is where it ended up:
https://flic.kr/p/uGWFE8
https://flic.kr/p/uGUg1x

I used a Hopkins 46365 short-proof taillight converter above the amplifier on the driver's side
https://flic.kr/p/uUNyur

I used the OEM wiring & connectors from an MK3 trunk lighting harness to make the plug and play harness as outlined in this great thread. You can also use repair wires and connectors from the dealer, but this was cheaper for me. The harness was either wrapped in cloth tape or shrouded in split loom depending on where it was (sorry, I didn't take pics of wiring routing):
https://flic.kr/p/uCdAxd

The power adapter went to the passenger side by the 12V plug (on this side in the Golf). I used the both the power and ground in the power plug instead of the taillight since I was already running the wiring across.
https://flic.kr/p/uCdJM7
https://flic.kr/p/tXMHG5

The plug goes out the center hole through the grommet and is mounted discretely behind the chain loops using Hopkins 48595 4Wire Flat Mounting Bracket. Here's a view from the bottom of the car:
https://flic.kr/p/tV9NZ4

Final product!
https://flic.kr/p/uGM5WE

 

[skoullias]

Great thread. I outsourced the work on my B5.5, and thus the self-deliberation about many of the details. While the bumper was cut further out that I would have liked, I didn't have to make the decision (so, it hurt less, I guess). My converter is also mounted in a similar position, but is wired to the circuitry. Those using your technique (with the lighter adapter) on an 04-05 Passat would have to mount it on the passenger side, as that's where the lighter outlets are.

 

[john.jackson9213]

Saw this installation in person on Saturday.

It looked great! Very neat. Much better than what Uhaul or such would have done. The trim around the receiver looked especially neat. There is enough room to access the pin and it does not look like a hack job. Very much a factory look. Excellent install of the wires also.

Congratulations on a job well done!

 

[SFHGolfTDI]

Saw this installation in person on Saturday.

It looked great! Very neat. Much better than what Uhaul or such would have done. The trim around the receiver looked especially neat. There is enough room to access the pin and it does not look like a hack job. Very much a factory look. Excellent install of the wires also.

Congratulations on a job well done!

Thanks, John! Nice to meet you and other club members. Even though I've been a longtime and active forum member, this was my first gtg believe it or not.

 

[SFHGolfTDI]

Great thread. I outsourced the work on my B5.5, and thus the self-deliberation about many of the details. While the bumper was cut further out that I would have liked, I didn't have to make the decision (so, it hurt less, I guess). My converter is also mounted in a similar position, but is wired to the circuitry. Those using your technique (with the lighter adapter) on an 04-05 Passat would have to mount it on the passenger side, as that's where the lighter outlets are.

Thanks for sharing your thread. The guys I went to would have preferred doing what your welder did, and just weld it on to the car. From what I've seen with hitch fabricators, most of them do it that way. I wanted mine to be completely reversible in case I ever went to a euro hitch or want to sell the car.

The fabricator made it clear that that he doesn't like it when "people like me" come in with specific instructions (exact words, "enthusiasts with $7k car that he thinks is amazing" and "its always the guys with the German cars." lol. Guilty I guess). Once we got over that, he did a fine job, and the only bummer was my slightly off measurement of where the hitch pin hole ended up, which isn't a huge deal.

In the end, between the fabrication, converter, wiring, etc., I'm definitely in a bit more than I had hoped, around $450 (hitch fabrication $245 + $30 to upgrade to 3500# capacity + $20 for lifetime warranty + $60 when I went back to have bumper support mounted). This could have bought me a euro hitch for sure (shipped price around $330 from www.transportsysteme24.de, plus the same costs for converter wiring and all that). But since my main use is my bike rack, I would have also had to buy a new euro compatible bike rack and would have been looking at closer to $800+, or would have had to figure out some kind of adapter solution for a 2" receiver US bike rack, with added fabrication costs.

Maybe I should have gone the euro route, and had I known about the total cost, I might have. But this works great for now, and I have a versatile 2" receiver. And if I ever want to switch to euro for any reason, I can sell or swap this setup.