Painless Harness Hole Cutout??

[muddpile]

I got my painless harness in the mail today, and I was going to cut the hole in the firewall bigger tonight with the supplied template. I taped it to the firewall over the old square hole, and immediately saw a problem. One of the 1/4" holes you have to drill is on that curved/stepped up spot on the firewall, to the left of the original hole. What do most people do, just weld the old hole shut and move the fuse box to the right so it mounts flat, or is there a better solution? Thanks!

[Southedisto]

I moved my template around until it nearly cleared it. IIRC one bolt is still just on the bend of the firewall.

[muddpile]

So it worked fine with that one bolt on the bend? If so, that is way easier than more welding.

[Southedisto]

Worked on mine, I'll double check in the morning.

[stsalvage]

I can't stand Painless Me i like the factory harness i've done 6 trucks and 2 Camaros and 3 Nova with the factory replacement No problems i did not have to cut or connected anthing thing my harnness is Painless all i have to do it plug it in i will never have a short or get moyster inside it I like factory Factor worked for 45 years the driect replacement had no problem

[muddpile]

The Painless harness looks like a top quality unit to me. It has updated blade fuses, well marked wires, quality terminals, and does not have large melted areas like my hacked up stock one

[edmonton72]

I'm installing a painless harness too. Just got 2 weeks ago from summit. I didn't know you had to modify the hole in the fire, it looked close too the same to me, I thought just the holes for the boles were different.

[topnos]

One thing to consider is the quality of the wire. The Painless kit, including EZ Wire and Hot Rod Wire, are better quality than the factory type of wire. From experience, the aftermarket kits seem to work better in regards to the electrical system (i.e. brighter dash, etc...). However, if factory appearance is your gaol, there is no substitute for factory replacement or the original harness rebuilt.

[cooters]

i bought a painless harness because it is easier than hacking a factory harness to add an msd ignition, electric fans and fuel pumps.

[cbbs02]

I just replaced all the wires in my make shift 72 chevy 3/4 ton. I ordered the harnesses through mothertruckers.com, and had a few problems (not with the harness) all the wires meet or excede the factory specs and every option that i needed came included ei. hei, electric choke, power windos. all I had to do was disclose what i wanted and they make it custom for your app. and the price and ease of install is top notch this company is highly recomened by myself.

[BigSky71]

Originally Posted by Southedisto

I moved my template around until it nearly cleared it. IIRC one bolt is still just on the bend of the firewall.

Thats how I did it also. I think I ended up expanding the stock harness hole down and to the left.

[68 P.O.S.]

I bought a Painless harness a yr ago because the PO hacked the wiring and I actually had a small fire start while driving. The only problem I had w/ the harness was connecting the alternator. The directions were wrong for my internal alt so the truck wouldn't shut off. I had to disconnect 1 wire and it was fine. The rest of the install was problem free. I bought the 18 circuit so I can add cool ish later on. I love it.

[randomhero472]

question... if i'll be adding electic fans and air-ride suspension, would the 18 circuit painless kit work for me?

[diggertodd]

I went to the hardware store that had the chrome washers that are about 1/2 inch thick- spacer washers - clamped up with a vice grip and ground the angle into one side of the spacer - the bolt sits square on the washer - grind slowly and you wont blue the chrome plating.

[68 P.O.S.]

Originally Posted by randomhero472

question... if i'll be adding electic fans and air-ride suspension, would the 18 circuit painless kit work for me?

The 18 circuit harness does have connections for an electric fan. I don't believe it has anything for the air ride though. There's plenty of people here with bagged rides who could chime in on this.

[muddpile]

So, if looking at the firewall from the engine side, I move the template down and to the right as far as possible, It should clear, or at least it will with the help of a small spacer? I'll have to give it another look and see if that will do it. Thanks!

[chevybill]

What harness do you have?
The one I ordered for our model trucks fit the factory opening with a slight enlargement.

[muddpile]

I have the one that is supposed to fit our trucks, can't remember the number. 67001 or something like that I think? The hole needs to be enlarged a slight bit, but the one mounting hole will be on a raised part of the firewall, and that doesn't look right to me.