Hole into cab for wires?

[Loren]

Okay. I admit it. I have ALMOST too many accessories. Many of these require one or two wires from the engine compartment into a control box in the cab. I have pretty much used up all the space available in the original factory holes with the original factory grommets.



I now need to cut (with a hole saw), or drill, a second hole into the cab for wires. I would prefer a hole that's about one inch or so in diameter so I won't have to go through this again. The hole can be through the firewall from the engine compartment, or through the floor from the chassis area beneath the truck.



The truck that needs the hole is the 2000 model listed in my signature, but I would expect that the same procedure would also work for the 1995. My newer truck has the four-wheel, anti-lock brakes, so I can't go through the firewall near the master cylinder. That space is all used up. It also has the six-speed transmission, but there seems to be a reasonable amount of room around the transmission. That may be a possibility.



I will install some sort of grommet (suggestions are welcome) to seal the hole somewhat and to protect the wires. I will also run them through a piece of split plastic wire loom.



It would be nice if the wires enter the cab in a convenient, but invisible location, like under the floor carpet along an edge, or up behind the instrument panel.



Does anyone have any experience and/or suggestions on where and how to make this hole?



Loren

 

[M Barnett]

There is a great tool for punching a hole through sheet metal, but I can't remember what its called. You drill a small pilot hole and then insert the pilot in the hole. It is actually a die that you tighten and it cuts a nice hole as you tighten it. Much neater than trying to saw a hole. If you would find the right location for the hole and then go to a sheetmetal shop, I'm sure they would do it for very little. I would consider a split gromet, then you could replace it easily. ------Michael Az

 

[Fast 1]

Pop the rubber boot out that fits around the 4x4 shifter, mine just snaps out of place. Nice big flat area to use a 1 inch hole saw, and the wires, cables can be easily tucked under the entire shift shroud on the way to the dash. Worked perfect for me. I had a large snow plow harness of wires to route. The hole saw cut really smooth and a rubber gromet is a nice finishing touch.



Fast Coolers

Verlyn Fast

 

[illflem]

I was having the same problem with too many wires, couldn't fit anymore though the stock grommet. I like to experiment and am always moving sensors around. I finally pulled out all my wiring except the boost tubing and pyro wire and passed a 5' long section of multi-conductor cable though the grommet. The cable has twelve 14 ga different colored wires with a heavy duty extension cord type sheath over it, all the wires I will ever need. The ends of the new cable are just cable tied to an easily accessible place under the dash and hood. The cable was about $3 a foot from the hardware store, no big expense since I only needed 5 feet. Easier than drilling a new hole. If you do want to make a new hole the best way is to use a Greenlee Slug Buster punch, you just drill a small hole then tighten down the punch for a perfect hole. Electricians use these to make holes in breaker boxes, my local Ace hardware rents all sizes up to 2" for cheap.

 

[WestTN]

M Barnett

The gadget for puncing holes in sheet metal is called a chassis punch. They are made by Greenlee. You can get them from places like Digi-Key and possibly Graingers. It will be your best bet. Then you could use flexible electrical conduit and a plastic box mounted in a convenient locaction.

 

[kswieringa]

Hole with the boot

Their is a hole behind the passenger side kick panel. It goes out to the fender and you can go up through the hood hinge area. plenty of room and a 1" rubber grommet. I have 2 12 gauge and 1 10 gauge wire passing through mine and still room to spare. Works great to reach battery on pass. side LOL Open the door and you can see the boot near the hinge