Cross Van Wires
Tools Required
Hardware Required
Equipment Required
Bulk Items Required
Supplies Required
Wax and grease remover, paper towels, 10/3 round cable, 16/5 round cable, large split loom, medium and large anderson contacts, many colors of anderson covers, anderson roll pins
Quick Reference
Cable length is 18’ 6” for both
Instructions
- Get the 10/3 and 16/5 cable and wrap electrical tape around the two with the 10/3 cable a few inches longer
- Pull wires from the driverside from the hole in front of the rear wheel well.
- Push wires up through and as you can access them through holes in the body use those holes to keep the cable moving.
- It's a bit of a tight fit up through the corner and the first part of the center ceiling rib. It can be easier with 2 people but very doable with one. Just make sure the wires are able to flow easily into the wall without going over any sharp edges.
- You may need to push the wire around throuh some of the small holes in the center rib if it gets stuck. The last few inches it gets a little smaller and it might need more pushing around through the small holes. Once through pull out and into the van to about the length that it needs to be.
- Drill 2 1/8 holes on the rear side of the wall per photo. Follow up with a step bit that will take them to 3/4
- Insert big grommets into holes
- Push the end of the wire back into the wall and feed it down. You'll need to guide it down and sometimes need to stick your hand up in through the lower hole to grab it and pull it down.
- Pull wires down, take tape off and guide through grommets. Wires should be long enough to nearly touch the rear corner body rib
- Strip the ends of the 10/3 and 16/5 cable by carefully twisting the big cable cutters around the wire. The idea is to not go all of the way through and then when you bend the wire it will pop apart. This is to make sure not to damage the insulation on the wires inside the cable.
- Strip ends and crimp big Andersen terminals on the 10/3 wires and the small Andersen terminals on the 16/5 wires.
- 10/3 gets Black, White, and Grey (ground) Andersen covers. The 16/5 get Blue, Yellow, Black, White, Red covers.
- Insert roll pins into connectors to keep them together with a pair of needle nose pilars
- Slide 500mm long pieces of split loom over both the 10/3 and 16/5 cables at the roof corners and slide into place to protect the cables from edges.
Done looks like this:
