Just got a set of Rigid Duallys and working on installing them but I have a question. Don't have any issues with the majority of the wiring but what size hole needs to be drilled to mount the switch? I can't find this information. I think I am going to mount the switch on the pillar but not sure what size hole to drill. Only have one chance to drill the hole and I don't want to mess it up. Also, has anyone notched out the hole to match the notch on the switch so that the switch doesn't rotate? I plan on doing this but I won't if it's not necessary. Thanks.

 

We'll, I installed the lights and sent an email to Rigid asking about the hole diameter needed for the switch but I haven't heard anything back.

Now I am trying to route the wiring but can't seem to figure the best way to do this. It seems like the harness from the light is too short to try to stick down into the cowl and too large to fit in the crack between the cowl and the side fender. I've seen pictures where the harness from the light is fit through this space with the connection to the main harness underneath the cowl. Anyone have any ideas? I took the two screws out and lifted up the cowl but when I put it back down it really is smashing down on the wire. Too much in my opinion.

Also, where are people fitting the wires through the firewall? I don't see any grommet close.

Thanks for the help.

 

Don't know what year you have but if you pull the side panel off the dash there is a nice hole there to get wires through.

On the cowl side of things I had seen where people tucked the wires in between panels. Not only did I not like the look but it put too much pressure on the wires. Potential for a fire if you ask me. I ended up punching holes in the cowl and then used rubber grommets for a nice clean look.

 

When I installed my switch for my duallys, rather than using an appropriate drill bit, it just used a drill bit that was somewhat similar to that of the switch then slowly wallowed out in circles until I got a perfect fit looks great and haven't had any problems

 

I will pull the side panel off tomorrow night and see what it looks like. I was looking from the engine side but maybe this will give me a place to route the wires through.

Do you happen to have a picture of the cowl with the punched hole and grommet? Not sure what this looks like. Is the hole large enough to fit the connector through?

 

It still appears that the harness on the lights is too short. May be the mount that came with the lights. It is lower than some pictures I have seen.

Has anyone plugged in the harness above the cowl and then run the wiring harness into the cowl? I really dont' like to to do this, exposing the connection to the elements even though the connector is sealed. Just seems like in several of the pictures that have been posted the harness is pinched getting through the cowl. Even at the bottom of the connector. Maybe this is ok, I just think it is a concern. Any thoughts?

 

try using a unibit. you can carve out just enough each time to get the perfect fit.

 

That's what I did for my cb holes in te plastic. For the lights I have the te rr a pillar setup

 

I heard back from Rigid and they said a 3/4" hole is what is needed for the switch. But I think the advice here sounds good, I will start with a slightly smaller hole just to make sure.

I was able to route the harness to the front. There is a lot of extra harness length that I just pushed under the cowling. It's the extra length from light to light. I cable tied it to the supports in front of the wiper motor so it doesn't interfere and left the extra length on the driver's side. Any issues with doing this? It was getting too cold in the garage to finish so I will be remounting the lights tomorrow after work and connecting them. I also need to get a nut for the negative battery terminal to connect the ground to. There is a threaded post sticking up but no nut. The positive side has three threaded posts sticking up and they all have nuts, but the negative is missing.

 

Get a step drill bit. Cheap at harbor freight if you have one near you. And always start your hole small. You can always make it bigger. Goodluck!