Would you drill a hole in the side of your 90? - Defender Source
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Old November 11th, 2009, 09:46 PM
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Justin Tebbenkamp
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Would you drill a hole in the side of your 90?

So I'm getting ready to mount some lights on the roll cage. I'm thinking about running the wiring within the cage...drilling a hole underneath the cage mount on the drivers side fender...and through the grommet in the bulkhead. Has anybody done this? Bad idea? I'd just rather have the wires hidden!!!
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Old November 11th, 2009, 09:50 PM
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Jim Cheney
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I'd sooner pull the front cage, drill a small hole in the cage support, run the wires through that, up the center of the cage, and out a little hole drilled in the cage near the light tabs.
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Old November 11th, 2009, 09:59 PM
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Quote:
Originally Posted by JimC
I'd sooner pull the front cage, drill a small hole in the cage support, run the wires through that, up the center of the cage, and out a little hole drilled in the cage near the light tabs.
dido...

that way you will not be kick'n yourself a year later when the mod lost it's luster...

My thoughts are I never alter any on my D that can't be undone...but that's just me...
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Old November 11th, 2009, 10:06 PM
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Justin Tebbenkamp
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by underneath the cage mount..I meant to pull the front cage and drill where it bolts to the body
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Old November 11th, 2009, 10:11 PM
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Oh, then go ahead! The the mount is quite thick, but you won't need a very big hole. I think it will be fine, surprised no one has posted pix of it before. Post some when you do it, let us know how it comes out.
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Old November 12th, 2009, 08:42 AM
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Couldn't you drill holes for the wires at the base of the tabs and then combind the wires into one hand have that run out the little hole at the top corner of the cage by the windshield then down the inside of the a pillar behind the trim piece?
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Old November 12th, 2009, 08:52 AM
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Scariest thing I ever did was cut out the hole for the snorkle on my 110. Second scariest thing I did was learn how easy it is to do...
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Old November 12th, 2009, 09:37 AM
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Andrew Najarian
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Quote:
Originally Posted by JimC
I'd sooner pull the front cage, drill a small hole in the cage support, run the wires through that, up the center of the cage, and out a little hole drilled in the cage near the light tabs.
This is precisely what I did on my 110. It wasn't too difficult. I'm not sure about the 90 cage, but on the 110 I had to drill one near each light tab (actually the PO had already done this) then I drilled one at each corner where the A-pillar tube meets the header tube so that the wires could pass between the two. Then I had to drill one in the foot of each A-pillar tube and in the "under fender support bracket" on the vehicle. From there it was easy to run the wires where I needed them. You really need to run the wires with the cage off and leave slack. As you install it you can pull the wires through some more.

Make sure to touch up the bare steel where you drill. I drilled mine before sending the cage to powder coat, but at the very least I would make sure there is some touch-up paint on the bare metal so your cage doesn't start rusting.
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Old November 12th, 2009, 07:42 PM
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Personally, I don't think the cage needs any help..., meaning, I wouldn't drill any holes in that thing.. ever.
I know it does provide a super clean install to do so, and I really dislike shoddy wiring,.. however, I still would not and do not drill holes in the cage( besides, my boss would have my as_ if I did so.) Just my .02.
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Old November 12th, 2009, 10:17 PM
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Andrew Najarian
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I considered that, but I figured the only hole I would be adding that could potentially weaken it would be the one at the top of the A-pillar bar, but I figured it was small enough that it wouldn't be likely to make a huge difference in the tube's strength. That being said, I am constantly surprised at how little it takes to drastically alter the strength of a piece of metal.
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Old November 16th, 2009, 12:13 PM
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Don Andrews
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Quote:
Originally Posted by tebby
So I'm getting ready to mount some lights on the roll cage. I'm thinking about running the wiring within the cage...drilling a hole underneath the cage mount on the drivers side fender...and through the grommet in the bulkhead. Has anybody done this? Bad idea? I'd just rather have the wires hidden!!!
I have lights on my windshield cage - wires are run internally all the way through the bar and into the left side of the truck - no holes in the body.

It's definitely do-able, so don't drill anything in the body if you can avoid it.
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