Builds 1HNDRD build
- Thread starter skyblue
- Start date
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what light bar did you go with?
skyblue
SILVER Star
- Thread starter
- #85
Grrrr..
A frustrating evening on the project.
It started out good and I did end up making some progress but in between it got testy.
First I built my switch harness..
Then I strung it in to place..
Most of the wires go up to the main switch panel while a few of them are for my future switches (beside the mirror adjuster)
Then it got a bit frustrating...
A frustrating evening on the project.
It started out good and I did end up making some progress but in between it got testy.
First I built my switch harness..
Then I strung it in to place..
Most of the wires go up to the main switch panel while a few of them are for my future switches (beside the mirror adjuster)
Then it got a bit frustrating...
skyblue
SILVER Star
- Thread starter
- #86
I always knew I'd be challenged by stringing my main accessory harness above the headliner...
Good grief!
The side curtain airbag was in the way and the headliner itself is very difficult to flex down without kinking it. (if I'm not mistaken, the '02 and older are a little easier to un-fasten) I took extra care to not interfere with the airbag function.
Anyway, I did finally get it thru to just behind the 2nd-row door and got things mostly buttoned back up.
I was reinstalling the grab handle and one of the bolts snapped off inside the body so now I've got to hunt down an EZ-out and a bolt...
Next up I need to get the harness out onto the roof...
Wish me luck
Good grief!
The side curtain airbag was in the way and the headliner itself is very difficult to flex down without kinking it. (if I'm not mistaken, the '02 and older are a little easier to un-fasten) I took extra care to not interfere with the airbag function.
Anyway, I did finally get it thru to just behind the 2nd-row door and got things mostly buttoned back up.
I was reinstalling the grab handle and one of the bolts snapped off inside the body so now I've got to hunt down an EZ-out and a bolt...
Next up I need to get the harness out onto the roof...
Wish me luck
Last edited:
skyblue
SILVER Star
- Thread starter
- #88
I just went to the Toyota parts desk (dealership across the street from my business) to look for the little shoulder bolt that I snapped yesterday... Turns out I have to buy the entire grab handle assembly.
I'm going to try to use a regular Metric bolt instead but I first need to get the broken end out of the body... I'll try an EZ-out this evening.
I'm going to try to use a regular Metric bolt instead but I first need to get the broken end out of the body... I'll try an EZ-out this evening.
skyblue
SILVER Star
There should be two bolt holes available enough to run two sets of wires, these are completely separate from the mounting holes, in other words free of use. Whatever you do don't drill thru the roof no need to do that. Remove that black trim it pops off and you'll immediately see all the available holes.
skyblue
SILVER Star
- Thread starter
- #94
Thanks again @savirc...
I propped up one side of the rack and removed the trim. There are 3 extra bolts under the trim which was great to see. However, none of them were in an easily accessible spot. (so far, I haven't needed to drop the entire headliner)
Clearly the Toyota engineers did not plan for me doing this...
I tried everything I could think of to get four 16ga wires thru one of the holes with no luck. Finally I had the idea to strip the insulation off all 4 of them for about 4 or 5 inches and twist them together. It worked! 4 wires is a very tight fit and I still need to test them to make sure they weren't damaged by all the pulling.
This is toward the front of the 2nd row door... I'll run the other 3 thru the hole behind the door and re-install the bolt in the other hole pictured above. I don't think it'll be nearly as much trouble for the remaining wires as 3 should be a lot easier than 4 to get started thru the hole. However accessibility was half the battle on this one and it's at least as difficult on the other. I should be able to get that completed tomorrow.
Once that's done I can start running the wiring to the rack lights locations. That'll feel like real progress.
Meanwhile, the fuse/relay panel has been laying on the work table in a half-finished state.. Hope to get that wrapped up soon as well and also get the aux battery installed. At that point I can start connecting everything up.
Later...
I propped up one side of the rack and removed the trim. There are 3 extra bolts under the trim which was great to see. However, none of them were in an easily accessible spot. (so far, I haven't needed to drop the entire headliner)
Clearly the Toyota engineers did not plan for me doing this...
I tried everything I could think of to get four 16ga wires thru one of the holes with no luck. Finally I had the idea to strip the insulation off all 4 of them for about 4 or 5 inches and twist them together. It worked! 4 wires is a very tight fit and I still need to test them to make sure they weren't damaged by all the pulling.
This is toward the front of the 2nd row door... I'll run the other 3 thru the hole behind the door and re-install the bolt in the other hole pictured above. I don't think it'll be nearly as much trouble for the remaining wires as 3 should be a lot easier than 4 to get started thru the hole. However accessibility was half the battle on this one and it's at least as difficult on the other. I should be able to get that completed tomorrow.
Once that's done I can start running the wiring to the rack lights locations. That'll feel like real progress.
Meanwhile, the fuse/relay panel has been laying on the work table in a half-finished state.. Hope to get that wrapped up soon as well and also get the aux battery installed. At that point I can start connecting everything up.
Later...
skyblue
SILVER Star
- Thread starter
- #95
So the most difficult & frustrating part of the wiring is complete...
For anyone who may follow in my footsteps.. Don't follow my footsteps. In hindsight, I should have routed the main roof rack harness down along the thresholds of the doors to just ahead of the rear wheel-well and then up the pillar. There's more space and it's way more accessible.
Getting the wires thru the bolt holes onto the roof is just simply a maddening task. But it's done and tested and working.
So here are some pics of the progress...
Interior all buttoned up (with only one crease in the headliner...
)
Stubborn wires thru roof.. (maybe 18ga would have been a better choice?) 2 locations
10ga pair to the rear for my future accessory panel
@REZARF suggested these for connecting the lights and said to thank him later... So I'm thanking him now...!
For anyone who may follow in my footsteps.. Don't follow my footsteps. In hindsight, I should have routed the main roof rack harness down along the thresholds of the doors to just ahead of the rear wheel-well and then up the pillar. There's more space and it's way more accessible.
Getting the wires thru the bolt holes onto the roof is just simply a maddening task. But it's done and tested and working.
So here are some pics of the progress...
Interior all buttoned up (with only one crease in the headliner...
)Stubborn wires thru roof.. (maybe 18ga would have been a better choice?) 2 locations
10ga pair to the rear for my future accessory panel
@REZARF suggested these for connecting the lights and said to thank him later... So I'm thanking him now...!
skyblue
SILVER Star
- Thread starter
- #96
I should provide a basic overview of the rack wiring...
Dual function light bar (2 wires + ground to RH side)
Side lights (1+G to each side)
Rear lights (1+G to rear corners)
Rooftop Tent interior light (1+G location TBD)
Random pics... The main wiring is all on the Driver's side and then I'll be running across in 3 places for the PS lights
Dual function light bar (2 wires + ground to RH side)
Side lights (1+G to each side)
Rear lights (1+G to rear corners)
Rooftop Tent interior light (1+G location TBD)
Random pics... The main wiring is all on the Driver's side and then I'll be running across in 3 places for the PS lights
skyblue
SILVER Star
- Thread starter
- #97
I snipped the plastic clips for the gutter trim to allow the wires to pas thru..
I mentioned in an earlier post that it was going to be difficult to reinstall the rack if it ever needed to be removed...
I was correct. Installing it the first time is relatively simple because you're basically assembling it in place.. The second time (I only had one side off & propped up) it's all one unit and a lot harder to get the bolts lined up & started. Then you've got all the slimy silicone on the spacers (which isn't a great design IMO) and it makes for a messy, difficult task. But I got it done! (one side) the other side should be a snap and then I can hook up the lights! (still need all the connections under the hood)
I can tuck the wires into the rack crossbars to go across to the passenger side. Not sure how I'll secure them yet but I'll come up with something. The black loom will pretty much make it all disappear in the black rack.
Overall I'm feeling like the wiring project is in the back stretch which is a good feeling. Another good feeling is that after many questions, YouTubing, and reading instructions, I have educated myself in the basics of 12volt wiring..! A month ago I knew basically nothing about it. Sure, I'm making mistakes as I go and having to redo some stuff but overall I'm happy with the results so far.
I mentioned in an earlier post that it was going to be difficult to reinstall the rack if it ever needed to be removed...
I was correct. Installing it the first time is relatively simple because you're basically assembling it in place.. The second time (I only had one side off & propped up) it's all one unit and a lot harder to get the bolts lined up & started. Then you've got all the slimy silicone on the spacers (which isn't a great design IMO) and it makes for a messy, difficult task. But I got it done! (one side) the other side should be a snap and then I can hook up the lights! (still need all the connections under the hood)
I can tuck the wires into the rack crossbars to go across to the passenger side. Not sure how I'll secure them yet but I'll come up with something. The black loom will pretty much make it all disappear in the black rack.
Overall I'm feeling like the wiring project is in the back stretch which is a good feeling. Another good feeling is that after many questions, YouTubing, and reading instructions, I have educated myself in the basics of 12volt wiring..! A month ago I knew basically nothing about it. Sure, I'm making mistakes as I go and having to redo some stuff but overall I'm happy with the results so far.
1.5" spacers all around? are they the steel or aluminum ones?
No rubbing with the 295s
