Best route to run large cable to cargo area?

[sdnative]

I am getting ready to run power to the rear cargo area of my 2003, and am trying to figure the best route to run the wire. I will be using either 4ga or 2ga for this application. The termination point will be somewhere close to the PS wheel well hump, either in one of the cubbies or on the side of my ARB drawer.

I normally would go through the firewall on the PS by puncturing a hole in the rubber nipple, then down along the door sill. My concern is that the wire would be too big to tuck in there nicely.

I am also considering going under the truck somewhere and poping up through the plastic grommets in the rear cargo area. There are at least 4 that I can see, two right behind the 2nd row seats and two behind the 3rd row seats. If I went this route, I was considering either running the wire inside some liquidtight nonmetallic conduit or wrapping the wire pair in some split loom then wrapping in electrical tape. My concern with this method is the sharp edges and the double 90 deg bends coming up through the floor.

I would love to see how others have managed this, pictures would be great. I have searched but couldn't find exactly what I was looking for. I do remember seeing pictures or a thread somewhere while surfing MUD in the past, but can't seem to find them now.

Is there another way that I am not considering? TIA.

 

[duggy]

I punched a hole through the grommet in the firewall and have had no issues with 4GA wire. I ran it through the passenger side door sill and terminated at the rear cargo section where I have my platform.

I probably won't win any beauty awards with this setup but it works beautifully.

 

[TXLX100]

X2 on going through firewall and down passenger bottom. Or you can go under the truck and come up near the second row, there is a body plug there.

 

[mtnracer]

I think I have 4 GA. Mine goes through the PS and down and under the door sills. No issues and it fits perfectly flush.

 

[sdnative]

Thanks for the feedback. I will probably try run the wire inside the cab to better protect it. Anyone use 2ga? I am designing for 100A capacity at 3% loss. Going to power a fridge, a couple ham radios, a few 12V plugs and an inverter in the future.

 

[mcgaskins]

I have to pull out my ARB drawers to reinstall them with the side wings/trim kit, and I'm planning to run power underneath the truck up to the cargo area and bring it through one of the 3rd row seat mount bolts (you have to remove them to install the drawers anyways). I'm hoping to get a rubber plug to surround the cable to seal it from any moisture coming up through the floor. I don't have any big immediate plans, but in the future I'll install a fridge and an amp for the stereo and likely other things as I have time.

 

[duggy]

Thanks for the feedback. I will probably try run the wire inside the cab to better protect it. Anyone use 2ga? I am designing for 100A capacity at 3% loss. Going to power a fridge, a couple ham radios, a few 12V plugs and an inverter in the future.

2GA is pretty large and can be clunky to route but should work under the door sills. Tuck it nicely and you shouldn't notice it there.

 

[Sandroad]

Wow, 100 amps! Best wishes to your alternator is that's continuous.

 

[sdnative]

Wow, 100 amps! Best wishes to your alternator is that's continuous.

That's just a planning number

No, not continuous.

 

[Fallon 40]

Thanks for the feedback. I will probably try run the wire inside the cab to better protect it. Anyone use 2ga? I am designing for 100A capacity at 3% loss. Going to power a fridge, a couple ham radios, a few 12V plugs and an inverter in the future.

I ran 2 ga on PS under door sill back to the hump then ran 4 ga to DS. Worked fine.

 

[fireball]

I ran 4# power and ground back to the rear quarter panel area. Ran under the truck and came up through one of the OEM rubber grommets. Pretty sure I've posted this photo before

 

[sdnative]

I ran 4# power and ground back to the rear quarter panel area. Ran under the truck and came up through one of the OEM rubber grommets. Pretty sure I've posted this photo before

Very clean. Thanks for the pic, that's one of the ones I was looking for.

 

[skivan]

do you already have a stock 12v outlet on the DS rear? there was a post (can't find it now) about jumping the unused AHC circuit in the pass fuse panel under the hood (if you don't have AHC) and getting 50 amps to the rear outlet. Don't know if you really need 100amps but this could be an easy way to get half way there with minimal effort...

 

[TXLX100]

do you already have a stock 12v outlet on the DS rear? there was a post (can't find it now) about jumping the unused AHC circuit in the pass fuse panel under the hood (if you don't have AHC) and getting 50 amps to the rear outlet. Don't know if you really need 100amps but this could be an easy way to get half way there with minimal effort...

I'm not an electrical engineer, but that's probably not going to work well with a high amp draw. The wires for that outlet are like 16 or 14 gauge (thin). Take a look at what the power outlet fuses are rated for and stay below that number for anticipated amp draw.

 

[OregonLC]

I ran my 2ga pair down the driver's frame rail wrapped in flex loom. There is a 1" x 3" plastic cover below the brake light. Pop this out and drill two holes for the wires to penetrate. Pull the wires through and route to where the OE jack was for your rear fuse panel. Silicone around the holes for waterproofing. I can get pics if you need.