Firewall pass-through for wires - Toyota FJ Cruiser Forum
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post #1 of 6 (permalink) Old 05-10-2015, 03:29 PM Thread Starter
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Firewall pass-through for wires

I have a hand-full of electrical projects that I'm planning and had some time this morning to install a daystar firewall boot in my FJ so I thought I'd post the results. I'm not a fan of poking holes in factory boots so I like the idea of installing my own boot for my custom installations. On the FJ, there's a ton of room on the passenger side in the engine compartment to work and this lines up nicely with the space behind the glove box.

First step was to remove the glove box (there are plenty of guides on how to do that on this forum). To the right of all the white A/C components and behind some kind of electronics box, I could locate the 2 factory boots that I could see in the engine compartment. I also moved the electronics box to make more room, the bracket has 2 nuts on the top and one on the bottom, but I didn't disconnect any of the plugs. There is a space between these 2 boots and just above that would provide access. The daystar boot requires a 1.25" hole so I cut a piece of cardboard with that diameter and stuck it to the firewall where I wanted it with carpet tape.



There's just enough of a flat space in this area, but it's close. I didn't want to go much higher, like above the boot on the left, because it would make it tougher to access from the inside.

To drill the hole, I started with a 3/4" roto-broach (the biggest I have) so that I could capture as much of the shaving as I could. Plus, I think roto-broaches are amazing. I then finished it off with a uni-bit. I was able to clean up the inside of the hole with a deburring tool from the engine compartment.



Here's a shot from the inside. I didn't cut away much of the carpet. You can see a bit of a hole where I'll later run wires.



The boot was easy to install from the engine compartment.



I hope that helps if anyone is thinking about installing one of these daystar boots.
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Last edited by rwingnut; 05-12-2015 at 04:57 AM. Reason: Pictures not viewable
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post #2 of 6 (permalink) Old 05-10-2015, 06:14 PM
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Re: Firewall pass-through for wires

Yikes! No photos came through. We always want to see photos!

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post #3 of 6 (permalink) Old 05-11-2015, 07:56 AM Thread Starter
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Re: Firewall pass-through for wires

Yeah, you're right the photos didn't come through. I guess I need to read the instructions again. I uploaded the photos as attachments and linked to them. I'll try again this evening.
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post #4 of 6 (permalink) Old 05-12-2015, 04:59 AM Thread Starter
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Re: Firewall pass-through for wires

So the photos had shown up just fine on my home PC, but not at work. I added the photos as attachments to the post and replaced the links to point to the new files. At home, they show up double now. ???
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post #5 of 6 (permalink) Old 05-12-2015, 05:55 AM
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Re: Firewall pass-through for wires

Yes they do, thank you! I'm sure this will help several people (including me) for locating a proper pass-through area. Nice job.

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post #6 of 6 (permalink) Old 05-12-2015, 12:10 PM
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Re: Firewall pass-through for wires

Nice! I was planning on using that area for my 2nd fuse/relay box when I install a 2nd battery.

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