Warn VR EVO wire relocation

[Murphydog]

I am moving a Warn VR EVO to my ‘23 Rubicon. In my previous install the wires were mashed against the bottom of the grill. I am thinking of re routing the through the side of the control pack cover, see the red circle in the photo below. Anybody else done this? Recommended tool for cleanly cutting the plastic? Any gotchas?

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[Trav73]

Did you ever find a solution for this? I'm in the same boat just dealing with the winch wires rubbing off the paint on the front grill. Only other thing I can think of is picking up one of the new 2024 grills, but not sure I care for the look.

 

[Bill_BCNtoNY]

Did you ever find a solution for this? I'm in the same boat just dealing with the winch wires rubbing off the paint on the front grill. Only other thing I can think of is picking up one of the new 2024 grills, but not sure I care for the look.

I haven’t done it yet myself, so I’m following this, but sharing my plan in case it helps. I’m thinking:

1. Disassembling the plastic housing to inspect the wiring behind it
2. Measuring the wiring
3. Finding a grommet that measures 1in or 1.5in (just enough for the wires to pass through)
4. Measuring the wiring (measure twice and cut once - I’m quite the expert in botching this!)
5. Carefully cutting a hole in the plastic housing using an arbored hole saw of the right size, at low speed to avoid melting the plastic
6. Installing the grommet in place and rerouting the wires

 

[Murphydog]

Did you ever find a solution for this? I'm in the same boat just dealing with the winch wires rubbing off the paint on the front grill. Only other thing I can think of is picking up one of the new 2024 grills, but not sure I care for the look.

I used a dremel to cut the hole, and put an additional heat shrink over the wires. I used a finishing file to smooth the edges of the opening. The cutting wasn’t great, but once all installed it looks ok

 

[BUSHRVN]

That’s exactly what I did when I installed mine this week. Pull the cover off so you can see the molded screw mount underneath so you don’t cut into it. I then taped the bundle of wires then taped them again with the OEM fabric tape. Turned out good and doesn’t touch the grill at all. I’ve got all the cables in one bundle.
Unfortunately I didn’t take pictures while the cover was off. With loosening the cables on the relay, you can get them all pointing the right direction without any contact/ rubbing at the terminal post.
I use a drywall cutout tool(like a drill bit on a dremel) and a sanding drum on the die grinder to smooth it out on all my plastic cutting.

 

[Trav73]

I think this would work but not very cost effective, there is not much extra room really needed. WARN ships the VR with 4 AWG wire. This stuff is designed for car audio to sit flat under the carpet when running battery to amplifiers.

 

[Trav73]

That’s exactly what I did when I installed mine this week. Pull the cover off so you can see the molded screw mount underneath so you don’t cut into it. I then taped the bundle of wires then taped them again with the OEM fabric tape. Turned out good and doesn’t touch the grill at all. I’ve got all the cables in one bundle.
Unfortunately I didn’t take pictures while the cover was off. With loosening the cables on the relay, you can get them all pointing the right direction without any contact/ rubbing at the terminal post.
I use a drywall cutout tool(like a drill bit on a dremel) and a sanding drum on the die grinder to smooth it out on all my plastic cutting.

Very well done, clean install! I love Tesa tape.

 

[Trav73]

I think this would work but not very cost effective, there is not much extra room really needed. WARN ships the VR with 4 AWG wire. This stuff is designed for car audio to sit flat under the carpet when running battery to amplifiers.

Well... now that I look at it. Don't think I'm going to get much out of the flat wire....

 

[CopperMtnGuy]

I didn't relocate anything and I ran mine under the grill and filler plate, wrapped in black electrical tape.

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