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Wires Through The Firewall - The Right Way!

Discussion in '2nd Gen. Tacomas (2005-2015)' started by webdr, Feb 1, 2018.

  1. Feb 1, 2018 at 8:33 AM
    #1
    webdr

    webdr [OP] www.gunnphotoservices.com

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    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:
    20180201_103556.jpg

    Harbor Freight Stepped Bit:
    20180201_103750.jpg

    I purchased the Daystar Firewall Boot for around $16, and a large stepped drill bit 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:
    20180201_104307.jpg


    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:
    20180201_110000.jpg

    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!
    20180130_150803.jpg
     
  2. Feb 1, 2018 at 8:40 AM
    #2
    Drainbung

    Drainbung Somedays you are the show....

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    Kudos to you sir, nice find, good job!
     
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  3. Feb 1, 2018 at 8:42 AM
    #3
    ChadsPride

    ChadsPride Tacoma Owner & Enthusiast

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    Cool setup!!! I may do this with the massive harness I'm about to make.
     
  4. Feb 1, 2018 at 8:46 AM
    #4
    Gunshot-6A

    Gunshot-6A West Coast Randy

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    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!
     
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  5. Feb 1, 2018 at 8:48 AM
    #5
    DrFunker

    DrFunker Prisoner of the little people circus.

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    The far side.
    Terrific! :thumbsup:
    Thanks. :hattip:
     
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  6. Feb 1, 2018 at 9:09 AM
    #6
    webdr

    webdr [OP] www.gunnphotoservices.com

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    I can only imagine... that boot is a PIA!
     
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  7. Feb 1, 2018 at 9:18 AM
    #7
    M192

    M192 Well-Known Member

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    Wish I would've seen this like 2 years ago. :facepalm:
     
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  8. Feb 1, 2018 at 9:32 AM
    #8
    Gunshot-6A

    Gunshot-6A West Coast Randy

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    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.
     
    DarkMark340 likes this.
  9. Feb 1, 2018 at 9:46 AM
    #9
    badger

    badger Well-Known Member

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    Nice tip, thank you. I've jammed my last wire through the existing pass throughs. They are packed !
     
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  10. Feb 1, 2018 at 9:54 AM
    #10
    JdevTac

    JdevTac Bawnjourno

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    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.
     
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  11. Feb 1, 2018 at 9:59 AM
    #11
    MattCowsmasher

    MattCowsmasher TTC #0010

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    Great write up!! For those who have already cut plumbers putty makes great sealent also won't harden like silicone.
     
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  12. Feb 1, 2018 at 10:00 AM
    #12
    Sandyman

    Sandyman Well-Known Member

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  13. Feb 1, 2018 at 10:19 AM
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    gsxrdoug

    gsxrdoug 2006 DCSB

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    Thank you.
     
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  14. Feb 1, 2018 at 11:03 AM
    #14
    Chase8059

    Chase8059 Kinda Well-Known

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    Dang, my trusty wire clothes hanger can be retired I guess.
     
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  15. Feb 1, 2018 at 11:40 AM
    #15
    webdr

    webdr [OP] www.gunnphotoservices.com

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    Ha! Yep, it's the last OEM crap in that line! But they'll stay for now.
     
  16. Feb 1, 2018 at 11:48 AM
    #16
    Bruce988jl

    Bruce988jl Well-Known Member

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

    Awesome find OP!
     
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  17. Feb 1, 2018 at 12:04 PM
    #17
    paranoid56

    paranoid56 Well-Known Member

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    the "right way" would have been to debur that hole you drilled :p
     
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  18. Feb 1, 2018 at 1:23 PM
    #18
    webdr

    webdr [OP] www.gunnphotoservices.com

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    De-burred like a boss! :spy:

    deburred.jpg
     
  19. Feb 1, 2018 at 1:28 PM
    #19
    Texoma

    Texoma IG: Triple C Chop Shop

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    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.
     
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  20. Jun 4, 2018 at 8:01 AM
    #20
    pmstoy10

    pmstoy10 Well-Known Member

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