Wiring Day The tunnel.
Gephyrophobia is anxiety or fear of bridges or tunnels. I have this issue. I have done this before, persevered but it is never easy to pull wiring out of a 911 without cutting or damaging. its even worse trying to put it back in.
So, How does this go? I admit I don't have pictures of all the steps. So I will try to describe in a haiku.
Pull wire through tunnel
Wire is caught, what now
Curse loudly at wire
Ok, maybe it is not that bad.
Step 1. Route battery power cable from trunk into footwell.
Step 2. Use a push tape to pull string from back of car, through tunnel into shifter area. I like to use the coated, woven layout string. You can find in the masonary section of your big box hardware supply. This time I had orange.
Step 3. Pull about 12 feet of fish string through tunnel.
Step 4. Tie a loop in the middle of the string to the starter ring terminal of the starter cable wire.
Step 5. Route wire through front access of tunnel, then into cable chase in corner of tunnel.
Step 6, Use string to pull starter cable through the tunnel from front to rear. Make sure to exit the correct chassis hole. Note wire pull gel works really well to slide wires through. Second note, you can not pull wires or string with wire pull gel on your hands.
Step 7. There should still be a lead of string through the tunnel. This will be used to pull the main harness from back to front.
Step 8. Carefully use about a mile of electrical tape to secure all wires on the main harness. There are 3 primary sections. Under dash, upper dash and fuse panel. Tape as tight as you can making the bundle as small as possible.
Step 9. Re route string in tunnel rear through bulkhead. Wire harness enters the large lower hole, goes underneath the metal conduit, then goes up into the cable chase. This gets tough to navigate correctly.
Step 10. Route harness under seat pan, over torsion tube behind trailing arm pickkups and into bulkhead hole. Hopefully the wire still has some bend markers so you know how fare to pull.
step 11. pull harness into cabin. At this point it will look something like this.
Step 12. Use string to pull wiring through cable chase inside tunnel. From the driver's side of the car This is a pull with left hand, lube wire with right hand (pull gel, get your mind out of the gutter) and also feeding with your right hand. I found that if I pull back about an inch I could then feed 3-5 inches at time. Work it through. It will eventually fit .
In the end, the harness will pull out of the tunnel access all the way at the front.
Step 13. Declare victory!
Now there is more clean up to do. Back in the rear you have to reset the cable cover to the access hole. Not done here.
You also have to push the other end of the harness between the rear seat pan/fire wall and the rear shock tower. Then you can secure the harness in the factory cable captures. Good thing I welded those back on when I replaced the seat pans.
This is the first step in wiring the car. Next I will be working on the frunk.