Wire Routing
 

I am installing a power inverter inside my Xj on the front passenger side, using 2 gauge wire for the power supply from the car battery. What is the best way to route the wires to the inside of the vehicle? Thank you.

Routing... that's pretty tough with 2 gauge on the passenger side. I presume you are running both power and ground, right? I think you are going to have to either go to the driver side and back again, or you are going to have to drill your own hole. Because of the AC/Heater equipment, it's going to have to be down low, which means it's going to have a lot of splash to deal with, so waterproofing is going to be critical.

On my 98 there is a wire bundle going through the firewall almost directly behind the battery, in the upper left corner of the firewall (as you look at the engine bay from the front), but I don't know if you can get to the other side of it or what might be in the way. I"m also skeptical of getting a pair of 2 gauge wires through there.

Where are you planning to mount the inverter? What size is it?

Ok I think I am going to try the hole on the passenger side. It is a 1500w inverter.

You don't need anything near as big as 2 gauge. 1500 watts at 110 volts is just under 14 amps. If your wire run is 10 feet, and you run 8 gauge, it's still overkill. You only get 0.10% voltage drop. That's nothing.

Even at 10 gauge, you still have only 0.17% drop.

Forget the 2 gauge. That's nuts. You're just wasting copper. 14 gauge is plenty! 12 is overkill. So, you like overkill? Okay, so do I. So go 10 gauge.

You should be able to get the 10 gauge through there with no problem. 2 gauge? I doubt it. 8 gauge would be difficult.


If you have a propane torch, pick up some fish tape. Cut off a 5 foot section, and heat one end red hot, then form a very tight loop with it. (A good pair of needle nose pliers work well for this.) Sharpen the other end on a grinder or with a file. Attach your wires to the loop end, and poke the sharp end through the grommet. Doesn't hurt to put a small glob of silicone dielectric grease on the grommet and push through that. The wire will pull through easier. You can angle the fish tape down into the passenger compartment and you should be able to grab it from inside. MAKE SURE YOU DISCONNECT YOUR BATTERY FIRST. You don't want to poke that fish tape into a connector under the dash and then ground the other end. If you get resistance while you are pulling, don't yank! You might wreck something.

When I used to install cellular phones (back when they were installed in cars) and business radio equipment, I always had 3 or 4 fish tapes in different lengths for such jobs. I went one step further and brazed the loops closed. That way they couldn't catch on anything.

I was able to get the wire threw just fine ounce I got the rubber grommet removed. I made my own seal with a nice thick flat piece of rubber and some sealant around the wires. Thanks for the help.

Pics or it didn't happen.

I can take some pictures in a week or so. I do not store my XJ at my house and maybe next week on my off days I'll be back where she is stored. You are correct about the 2 gauge being big and perhaps overkill but the manual for the inverter recommends 2 gauge wire for 6 feet long cable.