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: ted@jag-lovers.org
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