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06-04-2011, 05:58 PM
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#1 |
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Registered User
 Join Date: Feb 2007
Location: Tallahassee, FL
Posts: 322
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cut hole in firewall for Painless Wiring Harness?
It looks like I'm going to have to cut the hole in the firewall bigger for the Painless Wiring Harness. From about 2 1/4 " square to 2 1/2 " square?
Does anyone have instructions / advice on the best way to do this? Thank you, Tom |
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06-04-2011, 06:19 PM
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#2 |
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Active Member
Join Date: Jul 2007
Location: Centrally located between Houston, Austin and Waco. BCS area.
Posts: 7,947
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Re: cut hole in firewall for Painless Wiring Harness?
Are you sure?
I don't have an answer but I thought "Painless" meant you didn't have to do any major surgery. I was looking to replace the wiring on my 69 but now I'm going to have to take another look. I sure don't want to have to do any sheet metal cutting. |
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06-04-2011, 06:24 PM
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#3 |
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Registered User
Join Date: Feb 2003
Location: Paragould, Ar
Posts: 571
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Re: cut hole in firewall for Painless Wiring Harness?
You have to enlarge the factory hole I believe. It was not that big of a deal.
I masked it off and used a grinder w/ a cut off wheel.
__________________
1970 Gmc Grande Sierra Swb 2wd LSX (LQ4/4L80e) 1990 K1500 Daily 
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06-04-2011, 07:23 PM
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#4 |
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Senior Member
Join Date: Feb 2011
Location: Clovis Ca.
Posts: 632
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Re: cut hole in firewall for Painless Wiring Harness?
I made copies of the templet in the back of the instructions for the hole tape in place mark with a scribe , then use a die grinder with grinding wheel to open it up. Start checking whin you get close .
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06-04-2011, 07:30 PM
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#5 |
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Registered User
Join Date: Mar 2011
Location: Valley of the Sunstroke, Arizona
Posts: 1,210
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Re: cut hole in firewall for Painless Wiring Harness?
You'll need a 2.5" square firewall hole saw... very hard to find.
__________________
My build thread - Devastation and Reform http://67-72chevytrucks.com/vboard/s...d.php?t=567131 |
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06-04-2011, 11:43 PM
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#6 |
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Registered User
Join Date: Feb 2007
Location: Tallahassee, FL
Posts: 322
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Re: cut hole in firewall for Painless Wiring Harness?
LOL Desertcat - I've been looking for that square hole saw for a while now. Thanks guys. I'll give it a try tomorrow.
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06-04-2011, 11:54 PM
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#7 | |
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#16876
Join Date: Apr 2005
Location: Auburn WA
Posts: 12,266
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Re: cut hole in firewall for Painless Wiring Harness?
Quote:
__________________
Posted via Stationary Device '71 Custom Deluxe C-20 402. '67 Buick Special 455. '49 Plymouth Special Deluxe. "I love that old car smell"  Some people are like Slinkies... not really good for anything, but they still bring a smile to your face when you push them down a flight of stairs. |
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06-05-2011, 09:34 AM
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#8 |
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Registered User
Join Date: Oct 2009
Location: Denton, Texas
Posts: 1,735
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Re: cut hole in firewall for Painless Wiring Harness?
I also have a painless wire harness. I used a Dremmel with a cut off wheel. It really wasn't a big deal. Took me around 20 minutes. The best part about re-wiring the truck is no more funny little electrical gremlins anymore. I installed mine at least 7 years ago and have not had a single problem since. I knew it was time to re-wire when my headlights and dash lights started flickering. It probably would be bad to lose the headlights while driving at night.
Good luck! Keith |
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06-05-2011, 10:36 AM
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#9 | |
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Active Member
Join Date: Jul 2007
Location: Centrally located between Houston, Austin and Waco. BCS area.
Posts: 7,947
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Re: cut hole in firewall for Painless Wiring Harness?
Quote:
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06-05-2011, 11:28 AM
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#10 |
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Msgt USAF Ret
 
Join Date: Jan 2005
Location: Kalamazoo, Michigan
Posts: 8,718
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Re: cut hole in firewall for Painless Wiring Harness?
Here's the painless manual and the template is on the last page. There is tons of great information here but beware some of it is for fords and mopars.
 http://www.painlessperformance.com/Manuals/10104.pdf
__________________
VetteVet metallic green 67 stepside 74 corvette convertible 1965 Harley sportster 1995 Harley wide glide Growing old is hell, but it beats the alternative. |
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06-05-2011, 07:35 PM
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#11 |
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Registered User
Join Date: Feb 2007
Location: Tallahassee, FL
Posts: 322
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Re: cut hole in firewall for Painless Wiring Harness?
Thanks guys. I wound up using a dremel tool. It wasn't bad at all. Here's some pictures.
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06-05-2011, 07:39 PM
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#12 |
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Registered User
Join Date: Feb 2007
Location: Tallahassee, FL
Posts: 322
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Re: cut hole in firewall for Painless Wiring Harness?
A few more pictures.
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06-05-2011, 07:55 PM
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#13 |
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Registered User
Join Date: Oct 2009
Location: Tampa Bay
Posts: 1,549
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Re: cut hole in firewall for Painless Wiring Harness?
Looks good FLcustom10, Are you gonna start a build thread?
__________________
CHEVY/GMC VIN DECODERS |
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06-05-2011, 08:12 PM
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#14 |
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Registered User
Join Date: Feb 2007
Location: Tallahassee, FL
Posts: 322
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Re: cut hole in firewall for Painless Wiring Harness?
Thanks Bruceman. It looks like I do need to start a build thread. I'll try to get it going soon.
Tom Last edited by FLcustom10; 06-05-2011 at 08:12 PM. |
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06-06-2011, 10:31 PM
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#15 |
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Senior Member
Join Date: Feb 2011
Location: Clovis Ca.
Posts: 632
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Re: cut hole in firewall for Painless Wiring Harness?
That is just how I did mine. Now just take your time when routing your wires to make the harness.
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06-06-2011, 11:29 PM
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#16 |
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Senior Member
Join Date: Aug 2002
Location: Valley Center KS
Posts: 3,524
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Re: cut hole in firewall for Painless Wiring Harness?
a body saw would do it real easy
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06-07-2011, 06:36 PM
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#17 |
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Registered User
Join Date: Feb 2007
Location: Tallahassee, FL
Posts: 322
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Re: cut hole in firewall for Painless Wiring Harness?
Thanks guys. Bruce here's my build thread. I'll just have to add to it a little at a time. I look forward to reading yours too.
http://67-72chevytrucks.com/vboard/s...d.php?t=468335 |
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