Help Wiring 0 gauge

[jbacon47]

My Bronco is a manual, so it does not have the easy grommet/port on the firewall. It’s used by the clutch. The main wiring harness has a grommet nipple but it is only 1/4in wide… How can I run over 1/2in thick 1/0 gauge wire through the firewall? Anyone have suggestions? Or ideas? Can I go under the vehicle?

I’m considering abandoning this idea and just buying smaller gauge wire.

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[RoverDude]

Out of curiosity, why that gauge wire?
More specifically, what's it for?
If that's what you need, I just wouldn't go smaller because it fits.
Some background would be helpful.

 

[CalvinT]

If you determined you need a 0 gauge wire, why would you go smaller just for convenience? Unless you oversized when you selected 0 gauge wire, you're asking for trouble.

 

[CitrusBronco]

Put a hole in the firewall and use the appropriate size grommet, they sell them in many sizes and it will be just like oem quality when your done.

 

[jbacon47]

1000 watt amp/sub, and future proofing.. maybe a 3000watt inverter for tools.

 

[Brian_B]

My Bronco is a manual, so it does not have the easy grommet/port on the firewall. It’s used by the clutch. The main wiring harness has a grommet nipple but it is only 1/4in wide… How can I run over 1/2in thick 1/0 gauge wire through the firewall? Anyone have suggestions? Or ideas? Can I go under the vehicle?

I’m considering abandoning this idea and just buying smaller gauge wire.

You can get it through that grommet, but you need to cut a good sized slit / hole, use a bit of lube, and puuuulllllllll - just make sure you don't hurt the cable bundle that's already there, and probably touch it up with a bit of RTV afterwards to take care of the stretch marks.

Other option would be the grommet on the passenger side, but I think it's a bit harder to get at. Or going down around the frame and back up into the body, like back through the drain for the jack/cooler area or something - but you'd want to be very careful with that method and use some kind of armor / loom on the cable to help protect it.

Of you can just drill baby drill, since that seems to be the most popular topic of today.

 

[Bikeric]

I also have a manual and I was able to run my cable into the inner fender and down below the cab. From there I removed a drain plug and went back up into the cab and ran it to the rear right next to the cable tray. I don't have a great picture of where it entered the cab, sorry.

 

[jbacon47]

Interesting. I’ll think about this approach. Does the wire create a large lump? Under the washout interior?

 

[Bikeric]

Interesting. I’ll think about this approach. Does the wire create a large lump? Under the washout interior?

Not at all. I don't even know it's there.

 

[Area51BS]

Drill a hole with a step bit. Make sure to put wire in protective wrap. Use ferrules if putting wire into fuse holder type devices.
https://www.crutchfield.com/g_183750/Firewall-Bushings.html?tp=2161

 

[Karl_in_Chicago]

My Bronco is a manual, so it does not have the easy grommet/port on the firewall. It’s used by the clutch. The main wiring harness has a grommet nipple but it is only 1/4in wide… How can I run over 1/2in thick 1/0 gauge wire through the firewall? Anyone have suggestions? Or ideas? Can I go under the vehicle?

I’m considering abandoning this idea and just buying smaller gauge wire.

Grommet.
https://skyhighcaraudio.com/waterproof-grommets/

 

[Jdyount]

I mean how is this even a question. If there ain't a hole that your wire fits through, make one...

Go to Amazon, search "firewall grommet", pick out one you like, figure out how big the hole needs to be for that grommet, get a step bit and drill the hole, debur the hole, the firewall is steel so touch up the edges of the hole with some paint, put the grommet in the hole, then run the wire.

 

[indio22]

Some people will go to near any length to avoid drilling a hole. I got over that. My last car wire install has a nice grommeted hole drilled in the perfect location of my choosing. Drill baby drill.

 

[jbacon47]

Alright, I ordered a drill bit and grommet. Can anyone recommend an exact spot I should drill? Would be great to get practical advice or pics from someone who has actually done this before. Thanks

 

[Johnny Mo]

Alright, I ordered a drill bit and grommet. Can anyone recommend an exact spot I should drill? Would be great to get practical advice or pics from someone who has actually done this before. Thanks

I would look at both sides of the firewall and pick a location that looks like it is accessible and free from any possible interference when drilling from the chosen side. I'd likely look at the clutch pedal and where it comes thru and measure off from there and let it rip.

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