The largest and best supported Jaguar cars enthusiast site on the Internet!

Serving Enthusiasts since 1993
The Jag-lovers Web

Currently with 3,166 members

Wiring Tips

Wiring Tips

Here's a tip for getting your new wiring through the grommets and into
the sheet metal.

Remove metal from the factory hole. Take a small hand-held grinder, like a
Dremel tool, and carefully and uniformly enlarge the circumference of the
hole.  Say 1/16 to 1/8 inch.  You just need a small amount of additional
clearance to get the new wiring and grommet in the hole.   Carefully remove
a small amount off metal at a time and trial fit the grommet.  You do not
want to remove so much of the metal that the grommet will not stay in
place, of course.  So, go slowly and trial fit the grommet at stages.

The maximum amount of removal would be anything less than the thickness of
the grommet, i.e., od to id measurements.  Remember you don't have to
remove the maximum amount of sheet metal to get the wiring and grommet to
fit and have an original look.

After you have enlarged the hole and ready to complete fitment of the
harness through the hole, slip the grommet on the harness but away from the
hole.  Install the harness in its correcting fitting place.  Then, fit the
grommet into the hole.  You may have to wiggle it around but if all goes
well, it should fit and you can't tell that you have made the hole bigger
to fit the new harness.

I just finished rewiring my 150 FHC.  I enlarged four holes to take the new
wiring.  These were located at the cowl, which as you know is the largest
and most complex harness and which I fitted first; one on each side of the
front innner fenders which I fitted secondly for the engine and headlight
harness; and lastly, a hole had to be enlarged at the rear of the right
hand sill to house the body harness.

So, on the 150 FHC there are 4 holes which need to be enlarged to
accomodate new wiring.

Good luck.  Let me know if I can share my experiences and further help.
-  Bob Oates

If you have any questions or comments send e-mail to:
Main Page Back to the Library


Please help support the move to the new site, and DONATE what you can.
A big Thank You to those who have donated already!



Go to our Homepage
Improve your Jag-lovers experience with the Mozilla FireFox Browser!

  View the latest posts from our Forums via an RSS Feed!

Jag-loversTM Ltd / JagWEBTM 1993 - 2023
All rights reserved. Jag-lovers is supported by JagWEBTM
For Terms of Use and General Rules see our Disclaimer
Use of the Jag-lovers logo or trademark name on sites other than Jag-lovers itself in a manner implying endorsement of commercial activities whatsoever is prohibited. Sections of this Web Site may publish members and visitors comments, opinion and photographs/images - Jag-lovers Ltd does not assume or have any responsibility or any liability for members comments or opinions, nor does it claim ownership or copyright of any material that belongs to the original poster including images. The word 'Jaguar' and the leaping cat device, whether used separately or in combination, are registered trademarks and are the property of Jaguar Cars, England. Some images may also be Jaguar Cars. Mirroring or downloading of this site or the publication of material or any extracts therefrom in original or altered form from these pages onto other sites (including reproduction by any other Jaguar enthusiast sites) without express permission violates Jag-lovers Ltd copyright and is prohibited
Go to our Homepage
Your Browser is: CCBot/2.0 (, IP Address logged as on 26th Sep 2023 22:46:42