I finished mounting the auxiliary lights, the wiring, and the relay box installation (2 relays for the headlamps / Putco heavy duty harness), and 2 more relays, one for fog and one for driving lamps, in a Ford relay box that I pulled from a salvage Aerostar; I posted pictures of the progress in my Gallery Tech album named "1997 Ford Aerostar headlights").

Now I'm stuck at the firewall to run the wires for the Switch;

there are no unused holes with grommets, the hood release cable grommet does not allow for wires through it, I checked both the large bolted wiring "plugs" to see if wires could be run through it, no luck;

I think the only alternative is to drill a ½" hole and insert a grommet??

has anyone drilled through the firewall? I'm a bit scared to drill, not knowing what's on the other side, and looking at the firewall from the interior, there is almost zero space and impossible to know where the drill would come out if drilling from the interior. I know a spot where I could drill from the engine compartment, but when I go to the interior with a flashlight, can't figure what is on the interior side of the firewall, there is a huge support bracket right in the way.

some tips would be welcome, thanks.

 

Jose, take off the Carpet in the area left and a little above of the Pedals. A grey Foam layer lays behind the Carpet. You'll find a pre-perforated round Piece in the Foam, lift that Piece of and drill a Hole there. It comes out at the other Side between the Brake Booster Drum and the Relay Box. I did so to get an HiFi-Amplifier connected to the Battery. Such holes have sharp edges, so it's an good idea to wrap Tape around the Cable and fix the Cable with Zip-Teasers on both sides to pervent rubbing off the Isolation. Good Luck

 

ok, thanks! will check behind the carpet.

 

..pictures:



Perforated Piece placed back, german "Lüster-Klemme" or Cable ties to prevent the Cable from moving.



Outlet on the other Side of the Firewall, Lüster-Klemme/Cable ties.

 

wow, unbelievable! I don't know how I missed that cut-out. it is perfekt !! :-))

 

Yeah, you're welcome, keep left as possible from inside Footrest. It was pure luck not to damage the Brake Booster Drum when i've drilled. Little yellow Circle on the image is exact Drill Hole Location. Greets

 

very nice pictures, well light and focused.
hard to do under the dash of an Aero

 

I'm working on drilling the hole today;

after moving the perforated foam insulation cutout to one side, I can see a "raised round dimple" the size of a US $ 0.25 cent coin, about 1/4" inch to the right of the lower multi-wiring Plug, and about 1/4" inch above the bottom line of the multi-wiring Plug's factory hole. I think this is the point that waterbear is referring to;

the grommet I have is for a 3/4" inch hole, (0.75"), and this "dimple" seems to be exactly the size needed. I am using a step-drill bit, so I can stop drilling or enlarge the hole as needed.

I am measuring very carefully first.

 

Done!
if you want to see some pictures try to find my Gallery Album called: '97 Aerostar lights.

I don't know if it is in the Tech albums or Gallery Albums, I don't have a link to it.

Thanks to forum Member waterbear for the help

 

1. With right-click on the Picture in your Gallery, choose "Copy Image Adress"
2. In the Message Editor, choose "Insert Image"
3. With right-click on the "http://" Textfield, choose "Paste" ("http://" must remain highlighted blue)
4. Click "Ok" - the Picture should appear in the Message Editor and later in your message

Step 1


Step 2


Step 3


Step 4 - Click "Ok"

Cooper - I don't know if this procedure is allowed, just delete this message if so or make a Sticky from it

Nice Weekend alltogether

 

waterbear, thank you for these tips.

 

I got the wiring through the grommet, it is sealed with its cap and I added some black silicone caulking too.

the next step is installing two switches, one for fog lights, one for driving lights;
I decided against the Hella switch because the indicator lights are too bright at night. I tested the switch in the dark and for heaven's sake, it lights up the entire cabin with red or amber light! I like it dark.

so...I am looking for small diameter ½" inch max, very flush, black with tiny led, round, push-push switches at 15 amps unless 10 amps will do. I always find pictures of what I want from manufacturers in China, but never in the USA. Not Radio Shack, not autoparts stores, nowhere, and certainly not 12v.

am I asking for too much? Let me put it this way: it is a lot easier and faster to drill a ½" inch round hole, than to cut a square hole in plastic. That's the reason for my being so picky.