0g Wire Through Firewall: New Approach

Overview
Vehicle: 91 Eagle Talon Tsi AWD

• So you’re doing a battery relocation or just need to get some thick wire from engine bay to inside of car.
• Forget about trying to squeeze it through the pass side grommet (Engine harness pass through) or slicing into your steering rack boot.
• Make your own dedicated hole for 0g/2g wire to pass through firewall

Tools Required

• 0g Wire (as much as YOU need)
• Wireless Drill and drill bit set up to 1-1/16” (large step bits work fantastic)
• Dremel rotary tool with sanding drum
• Home Depot Grommet Kit (8pk CPGI Asrt)
• Can of fast drying paint (to seal drilled hole area)

Precautions
Measure before drilling
Carefully sand hole to remove sharp edges
Allow proper ventilation for spray paint

Steps

1. Inside vehicle, pull back carpeting on pass side floor and remove insulation material on floor.
2. About 2 inches to the right of the shift linkage cables bolt, there’ll be a flat spot.
3. Measurement reference with a tape measure.

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1. Drill a small pilot hole through the firewall. It will be a deep hole to the other side.
2. Once you’re through, drill out to 1-1/16” on both sides (from inside and in engine bay)

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1. Then use your dremel or whatever tool to sand down the sharp edges of your drilled hole.
2. After it’s sanded, mask the area and spray some paint to cover the exposed metal.
3. After it is dry, insert the large grommet from the Home Depot Kit into the hole.

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1. There will be a grommet for both sides of firewall (one inside and the other engine bay side)

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1. Hard part is done now. Go ahead and slide your 0g wire through.

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1. You’ll see how the wire easily slips through and is protected by the grommets.
2. Now you can neatly run the wire.

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In the past I searched for this same thing and couldn't find anything with pictures. So while I had the chance and some free time I snagged some pics.

Comments or questions, PM and I'll try to help out.
-Mike02rt