[The Maverick]

I will be running a DRL fuse tap into the fuse box under the hood. I am looking for ideas on the best spot to cut a notch in the lid and base of the fuse box to run the wire through. I haven't done this before but figured a Dremel would work.

Any suggestions on the location or method, or photos of examples of where others have run a wire into the under hood fuse box? Thanks!

[Uk2019]

Rather than a notch which kinks the wire and may cause problems with water ingress, I dried a hole in the lid and used a small rubber grommet.

[Uk2019]

Finished product looks like this

[arpad_m]

Originally Posted by Uk2019

Finished product looks like this

Very impressive work, Uk2019

I'd probably try to drill/cut into the box (adding grommets) and just notch the lid a bit to keep it 100% mobile as before, but that may be very difficult.

[ctrlz]

Originally Posted by arpad_m

Very impressive work, Uk2019

Agree, that looks great. You could also hit the backside with a dab of silicone to really seal it. Grommets visible on the outside, grommet + silicone on the inside.

[The Maverick]

Originally Posted by Uk2019

Rather than a notch which kinks the wire and may cause problems with water ingress, I dried a hole in the lid and used a small rubber grommet.

Thanks! I was thinking about how to incorporate a small grommet into the notch, but drilling would offer 360 degree coverage. I also wanted to select a location for the notch/hole that would best help deter water entry - but am still thinking over that part. The same general location you used is what I was thinking of.

[RamAir02]

Take a look at McMaster Carr for some grommets! Perhaps overkill, but you can measure the width of the fuse box and the gauge of wire you're using to really dial it in.

https://www.mcmaster.com/grommets/

[RCwhat]

Not for nothing but I’d use a cable gland instead of a grommet. I wouldnt want water getting into the fuse box and having an electrical issue that won’t be covered under warranty.

[RamAir02]

Originally Posted by RCwhat

Not for nothing but I’d use a cable gland instead of a grommet. I wouldnt want water getting into the fuse box and having an electrical issue that won’t be covered under warranty.

First I'm hearing of a cable gland. Just looked it up. Seems cool and probably a better solution than the grommet (perhaps even more overkill, but better safe than sorry)

[The Maverick]

So I am thinking of going the "gland" route - best protection and best look, I think. However, I can imagine a service tech down the road (or me, distracted in the middle of troubleshooting) lifting off the lid of the fuse box further than it should go with a wire running through it.

I was thinking that I could avoid that by using some of those tie strap anchors with foam tape bases, one on the base and one on the lid (with a zip tie through them) to make a "hinge" (and sort of a strain relief) to keep the lid from being lifted up to the point where it might kink or damage the wire.

Anyone tried anything like this?

[Uk2019]

I looked into cable glands but it's difficult to find one small enough (in terms of it's external diameter) to fit in the depth of the lid. In the past, when I needed to take my car to the dealer, I simply disconnected my wiring (as you can see in the pictures, I used bullet connectors to enable this) and replaced the grommet with a blank (sealing) grommet. Then just put my wire back afterwards. My wiring is for a homemade mild to wild controller for the npp exhaust and backup battery for the dashcam. I wired my drls in using the workshop manuals and headlight connector so didn't need a fuse tap in the fuse box.

[The Maverick]

Originally Posted by RCwhat

Not for nothing but I’d use a cable gland instead of a grommet.

Thanks for the suggestion! It was a tight fit, but I was able to get a PG7 fitting to work.

Originally Posted by Uk2019

In the past, when I needed to take my car to the dealer, I simply disconnected my wiring (as you can see in the pictures, I used bullet connectors to enable this) and replaced the grommet with a blank (sealing) grommet. Then just put my wire back afterwards.

I went with the bullet connectors as well to allow me to easily swap the original fuse box lid back in, if necessary.

[RCwhat]

Originally Posted by The Maverick

Thanks for the suggestion! It was a tight fit, but I was able to get a PG7 fitting to work.


I went with the bullet connectors as well to allow me to easily swap the original fuse box lid back in, if necessary.

That looks great and no worries about water intrusion. Good job 👍🏼

[Vtor_ZL1]

Hmm i'd try to run wire up through an empty slot. Not fan of wires through in the lid.