Wow, that’s amazing! I’m very glad you got it to work. Honestly I should have waited to see how yours turned out, but I was impatient and wanted to add the release at the same time as I did my fold down table. Now I’m stuck with just a simple paracord pull, though I’m working on getting my t handle to work better. I had a similar issue to you where it worked fine with the door dissembled, but then when back together it only sometimes worked and things were getting caught up. If I didn’t already drill a 1/2” hole on my door card id probably do your method. Really great work! Probably the best interior release I’ve seen yet.not being satisfied, I took everything apart again and pretensioned the cable with zip ties. two on the hasp side and one on the handle side.
not being satisfied, I took everything apart again and tried to figure out what was causing the issues.
View attachment 2510539
this is the throw of the factory latch being pulled.
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this was the throw of the truck latch being pulled. I decided there was a little more pretension that could be set and decided to use zip ties to take up the slack in the line. two medium sized zip ties on the hasp side and one on the handle side.
I also lashed the two cable's sheaths together so there was less slop in the throw of the cables.
View attachment 2510529
View attachment 2510530
now everything works cleanly.
On a side note, where’d you get the paracord interior handle? I broke one of the tabs on my OEM plastic handle and I’m thinking about maybe just doing one of those.