Filling in large holes

[KLF]

I got too busy at work and haven't been able to work on this for the past few days, but I did find something on the Fastenal site that might work, looks like they will even sell me one of them.

Splangy: PM sent.

 

[tag3]

Glad you found something.

 

[KLF]

Still looking. Fastenal was a bust, they will only sell me 2500 of them.

 

[ff347]

I had a hole like that in an old Blazer. I took a fender washer with some kind of RTV caked all over it ran a bolt through the firewall added another fender washer on the inside, tightened it and done. Had them sitting around and it never leaked and took no talent.

 

[KLF]

That's exactly what I did when I took the AC stuff out several years ago. But they got all rusty, I was looking for something a little more weatherproof. I may have to go back to the hardware store and get some stainless washers this time.

I am putting a bunch of gauges in when I put the interior back together, so having at least one hole with a rubber plug would be useful for running the sensor wires.

I can't believe how much of a PITA this is turning into.

 

[WarDamnEagle]

You need blind/plug grommets. Here are some sources: Blind/Plug Grommet on Minor Rubber

Blind Grommets

Rubber Grommets, Insulation or Push In Grommets, Mil-Specification Grommets, Vibration Mount Grommets, Blind and Plug Grommets

These look perfect if he has the right size:

Rubber Grommets

Btw, have you considered looking to see if Toyota has OEM plugs for those holes? I'm sure they sold that same model truck without AC and I'm sure the firewall had the holes drilled anyway.

 

[WarDamnEagle]

Looking at the front fender apron diagram on ToyotaDIY, I found two standard parts with the description "plug, hole". The part numbers are:

90950-01398
90950-01061

Both appeared to be available although at least one of the numbers has been superseded. I didn't write down the new number.

 

[KLF]

These look perfect if he has the right size:

Rubber Grommets

This one looks promising, looks like they will sell me singles. Problem is the $20 minimum order. He's in Japan, but I don't think that's a big deal. The other sites supply to manufacturers, they will want me to buy by the 1000's.

Btw, have you considered looking to see if Toyota has OEM plugs for those holes? I'm sure they sold that same model truck without AC and I'm sure the firewall had the holes drilled anyway.

I actually have been crawling thru the EPC looking for a factory plug that will work. I did find one in the floor of the truck that will work for the larger hole, so I'm all set there, it's on order from Sam. The problem with the EPC is they don't tell you the size. I actually started peeling up carpet in the car and the Highlander, looked in the trunk, looking for a match that will fill a 1" hole, nothin yet.

Trucks that came out of the factory without AC have no holes. This AC was actually installed by a dealer later on, you can tell the holes are not factory, they were obviously done with a hole saw, kinda jagged.

90950-01398
90950-01061

First one is too small (15mm). Second one is the one I'm using for the 1.5" hole.

 

[Splangy]

The guy with the body plugs wasn't at Amherst last weekend. I have some 1" plugs, and maybe a 1.5". Let me know if you find yourself in the Manchester area.

 

[ff347]

Found anything yet? What about a Mechanical Pipe Plug? Something common that most plumbing places/supply places should sizes and varities of.