Introduction
The Viper Roadster, known for its high-performance design and iconic styling, requires specialized modifications for enhanced functionality and convenience. One such modification is the installation of a door popper, an electric mechanism designed to remotely release the manual door lock, allowing for easier access to the vehicle. This article is based entirely on user-submitted experiences and technical notes from Viper Club members who have installed the door popper system on Viper models from 1993 to 1996. These firsthand accounts provide valuable insight into the installation process, common challenges, and practical solutions. The information is sourced directly from community forums and is presented in a structured format to assist U.S. consumers and DIY enthusiasts in understanding the process and potential pitfalls.
Understanding the Door Popper System
The door popper system for Viper Roadsters functions by electrically activating a solenoid that interacts with the manual door lock mechanism. This system is particularly useful for vehicles with central seat belts, where the door lock is not automatically engaged when the door is closed. The solenoid is typically mounted in the door panel and connected to the vehicle’s alarm system or key fob. When the unlock button is pressed, the solenoid pulls the door lock mechanism, allowing the door to open without manually rotating the lock.
The system comprises several key components: - Solenoid: A small electric motor that generates the mechanical force to release the door lock. - Mounting bracket: Used to secure the solenoid in the door panel. - Cable and hook assembly: Connects the solenoid to the door lock mechanism. - Wiring harness: Includes a ground wire and a hot wire for electrical connection.
The installation process involves mounting the solenoid, running the wiring through the door channel, and connecting the system to the alarm box or a switch. Detailed wiring instructions are provided, including tips for routing the wires through the rubber boot between the door and chassis.
Installation Challenges and Solutions
Several users have documented their experiences with the installation process, highlighting common difficulties and their solutions.
1. Wire Connection Issues
One of the most frequently reported challenges is establishing a secure connection between the solenoid wires and the alarm system. A user named Patrick Hiebert noted that finding a reliable connector for the alarm system’s male connectors was particularly time-consuming. He eventually used a crimped 22-gauge female connector and reinserted the plastic blue wire holders to secure the connection. To prevent the wire from popping out, he used zip ties to keep the wires snug.
2. Grounding Difficulties
Another user encountered significant difficulty in grounding the system. Initially, the instructions suggested grounding the wire to the seat belt retractor housing, but in this case, the housing was not connected to the chassis and did not provide a proper ground. After extensive testing, the user drilled a small hole in a cross member and used a self-tapping screw to create a reliable ground point. This solution required multiple attempts and considerable time to identify.
3. Routing the Trigger Wire
Routing the hot wire (trigger wire) through the rubber boot between the door and the chassis is a critical step in the installation process. A detailed method for this involves using a coat hanger to guide the wire through the boot. The steps are as follows: 1. Pull the boot loose from the chassis to eliminate the curvature. 2. Create a 180-degree loop on the feed end of the coat hanger and crimp it tightly to avoid puncturing the boot. 3. Tie a knot in the wire and connect it to the coat hanger with a 360-degree loop, crimped tightly around the wire. 4. Apply a small amount of soap or silicone to the knot to ease the pull-through process. 5. Pull the wire through the boot, feed it through the chassis hole, and reattach the boot to the chassis.
This method was found to be effective in avoiding damage to the boot and ensuring a smooth wire passage.
Mounting and Alignment of the Solenoid
Proper alignment of the solenoid is essential for the door popper to function correctly. Thomas Hayden described his method for mounting the solenoid in the door panel. After removing the seat belt roll-up mechanism, he drilled two holes in the outside-facing wall of the door at a 45-degree angle, angling them upwards toward the rear of the vehicle. This allowed for the bracket to be mounted in a position that aligned the solenoid with the door lock mechanism.
The solenoid was then connected to the nylon bushing arm located on the door lock side. A hook from the kit was used to connect the door lever to the cable. Hayden noted that the cable needed to be slightly tighter than recommended by the VPA instructions to prevent slack that could prevent the door from opening. In his case, he ended up cutting off half of the cable due to excess length and used the black cable cover, also shortened, to seal the solenoid’s entry point and prevent debris from entering.
Common Usage Tips and Precautions
Users have also provided several usage tips to ensure the system functions as intended and to avoid potential issues.
1. Avoid Locking the Manual Door Lock
One of the most important tips is to never rotate the manual door lock to the lock position when exiting the vehicle, especially when using the key fob to unlock the door. The electric opener will not release the manual lock, and attempting to do so may result in the door not opening when the key fob is used. This is analogous to how door handles function—they cannot release the manual lock if it is already engaged.
2. Ensure Proper Cable Tension
Proper tension in the cable connecting the solenoid to the door lock is crucial. A loose cable may not provide enough force to open the door, while an overly tight cable can cause mechanical stress and potential damage. As noted by one user, the cable should be slightly tighter than the VPA instructions suggest to ensure effective operation.
3. Seal the Solenoid Housing
To prevent dust, water, or insects from entering the solenoid housing, it is advisable to use the black cable cover provided in the kit. Cutting the cover to the appropriate length and securing it around the cable entry point can help maintain the integrity of the system and prevent potential malfunctions.
Troubleshooting and Maintenance
Although the door popper system is generally reliable, users have reported occasional issues that can be resolved with basic troubleshooting.
1. Door Popper Fails to Activate
If the door popper does not activate when the key fob is used, the first step is to verify that the wiring connections are secure. A loose or disconnected wire can prevent the system from receiving the necessary electrical signal. Users should also check the ground connection and ensure it is properly attached to the chassis.
2. Door Opens but with Delay
A delay in the door opening could indicate a loose cable connection or insufficient tension in the cable. Tightening the cable or repositioning the solenoid may help improve the response time.
3. Unusual Noises During Operation
Unusual noises, such as grinding or clicking, may indicate misalignment of the solenoid or worn components in the door lock mechanism. In such cases, it may be necessary to realign the solenoid or replace any damaged parts.
Regular maintenance, including inspecting the wiring and cable connections, can help prevent these issues and ensure the system continues to function reliably.
Conclusion
The Viper Roadster door popper system offers a convenient and effective solution for remotely unlocking the manual door lock, particularly for vehicles equipped with central seat belts. Based on user-submitted experiences, the installation process involves several key steps, including mounting the solenoid, routing the wiring, and ensuring proper alignment with the door lock mechanism. While the process can be technically challenging, detailed instructions and user feedback provide valuable guidance for successful installation.
Common challenges such as wire connection issues, grounding difficulties, and cable alignment have been documented, along with practical solutions that can be implemented. Users are advised to follow the provided tips carefully, including avoiding manual locking of the door, ensuring proper cable tension, and sealing the solenoid housing to prevent debris buildup.
By following these guidelines and learning from the experiences of others, users can successfully install and maintain the door popper system, enhancing the functionality and convenience of their Viper Roadster.