Wires Through The Firewall - The Right Way!

Kind of an arrogant thread title, right? I mean, who am I to judge!? Regardless, I was looking for a clean way to push an expanding bundle of wires through the firewall without stabbing holes through the existing rubber boot. Why am I against this easy method? Punching a single hole in the OEM boot works fine, but as your wiring needs grow, so do the random holes in the boot.

The Daystar Firewall Boot:


Harbor Freight Stepped Bit:


I purchased the

$15 Daystar, Universal Firewall Boot, Single, Accommodates 3/8" to 1" Diameter Wire Bundles, fits any vehicle that needs a wire loom, KU20040BK, Made in America , Black

Daystar Firewall Boot for around $16, and a from Harbor freight. There's a great spot above the OEM rubber boot, just to its 1 o'clock if you're looking at it head on from the engine bay.

1" hole drilled. You can go up to 1 1/4" for the boot:



Drill a small pilot hole, then use the large stepped bit to open the hole up to any size between 1" and 1 1/4". The only thing behind this spot is some loose carpeting. I popped the bare metal around the hole with some Rustoleum.

Daystar Boot installed and ready for more wiring:


The good thing about the Daystar boot is that you can cut away the stepped rubber as your wiring increases, and just ziptie it closed to prevent any water from entering (if you're the stream crossing type). I hope this helps you 2nd gen owners. Not sure if the firewall location is the same on a 3rd gen, but I'm sure the Daystar boot can be made to work.

Now it's time to get wiring!

 

Kudos to you sir, nice find, good job!

 

Cool setup!!! I may do this with the massive harness I'm about to make.

 

But this takes all of the "FU-n" out of trying to yank a switchpro plug, wiring and loom through a tiny slit in the side of the oem boot!

 

Terrific!
Thanks.

 

I can only imagine... that boot is a PIA!

 

Wish I would've seen this like 2 years ago.

 

It is actually pretty easy if you make a decent size slit with a pocket knife, run a straightened coathanger up from inside the cab, use a long screw driver to pry the grommet open a little more, and yard the cable in question through. Just takes a little time to get the "technique" down.

 

Nice tip, thank you. I've jammed my last wire through the existing pass throughs. They are packed !

 

I might eventually have to do this also. Il tired of poking holes in the main firewall boot, my 1 small grommet on driver side is full, my 2nd small grommet on pass side can only take a few more 12awg wires. And I don’t want to run shit down to the grommets that are under the seats.

I’m debating between a blue sea clamshell setup or the daystar boot. The only advantage to the clamshell is it makes running new wires through the same passthru a little more easier. But you have to do 1 big hole and 5 small holes instead of 1.

 

Great write up!! For those who have already cut plumbers putty makes great sealent also won't harden like silicone.

 

$15 Daystar, Universal Firewall Boot, Single, Accommodates 3/8" to 1" Diameter Wire Bundles, fits any vehicle that needs a wire loom, KU20040BK, Made in America , Black

https://www.amazon.com/gp/product/B004K2285E/ref=ox_sc_sfl_title_1?ie=UTF8&psc=1&smid=A5Q8NSB0BBCY2

Must be hazardous cargo, can't be shipped to Alaska. Imagine that.

 

Thank you.

 

Dang, my trusty wire clothes hanger can be retired I guess.

 

Ha! Yep, it's the last OEM crap in that line! But they'll stay for now.

 

Well shit.. I could have used this years ago....

Awesome find OP!

 

the "right way" would have been to debur that hole you drilled

 

De-burred like a boss!

 

I did something similar, but maybe a little cheaper. I drilled the hole in the same area with a hole saw, deburred it of course. Put a rubber grommet in the hole. Passed all my wife's through. Then sealed with plumbers putty on both sides. I've done this to a few vehicles with no complaints of leaks. Mine hasn't leaked either.

 

Nice! Perfect timing! I have a few more wires to run!