Look for PCV valve grommets at an auto parts store. There are some that fit 1" or larger holes. The i.d. won't be as small as 1/4", but not clear that you need a "snug" fit around the wire, since you're not trying to "seal" but simply to "protect" from chafing, etc. I used these when ran fuel hose through holes in the firewall of my Vanagon.

If you absolutely want the i.d. to be an exact, snug fit - hmm, get sheet metal hole plugs and drill the right i.d. hole.

http://www.clipsandfasteners.com/Flush_Sheet_Metal_Plug_Plastic_1_Hole_Black_p/a11749.htm
http://www.nutsandbolts.com/38-hole-size-plastic-flush-sheet-metal-hole-plugs-qty-100-p-816.html#googlebase

You know, it'd better not turn out that you're building some sort of chemical/biological weapon and making us all accomplices by providing part sources . . .

He is not smart enough for that...

- you must have already seen my burrito diet comment, eh?

I am guessing that every one of the FLAPS asked what type of car you were working on.

oh yeh - one had an older guy who knew what was up, but he was crippled by working for a large co. that does what they all do -- carries the high profit, high turnover items & not the 'junk' people need sometimes

this AM, went to Brooks - the local VW hotrod place that is also an old-timely sort of place; local, run by a local family (surely of - ah - Appalachian Origin, {jes' like both sides of mah own family}), has all sort os bins of stuff, carries 55 gal. drums of fill-your-own oil, 3 gens. of family work the store & the women know more than most franchise auto parts clerks, etc.

- well, they had a few things that I think I can make work, so today's task is to make 'em work (not to mention Sawzalling out some small slider windows downstairs, reviewing a bunch of scientific journals, and at 6 pm an important drinkin' event)

bug shops are the best for odd stuff....they are odd cars :)

What? You don't have a roll of duct tape? :p

Knockout plug. Standard knockout hole for 1 inch conduit connectors is 1.375 inches in diameter. Knockout plug fits very tightly against sheet metal. Drills easily. Cheap as sin.

Heck ,they even make non conductive ones now, and sandwich style ones with rubber (waterproof), all sorts of options. And your FLAPS will NOT carry them :p

mission accomplished - the quality is intermediate between the duct tape level and the true-blue perfect Pooshey level (perhaps fitting, as it is on a VW Vanagon)

now I gotta wire it up

Here's another alternative...
Seals-It

Randy, I saw these when I was looking at some recent pictures of Wayne's 959.

Shouldn't cost too much. :)


http://forums.pelicanparts.com/uploa...1274408585.jpg

We use the seals-it brand for racecar firewalls and such. They are stupid expensive but do a great job...

Don't those also require some extra, smaller holes for bolts or something?

The thing I wound up using tends to pop out of the hole, so I'm still in search of better solutions...