Ok I know this has been beat to death but I got to ask.

My 05 SuperCab XL has those stupid big modular plastic plugs between the door and doorframe instead of the easy-to-live with rubber boot. I have a couple of mods that I want to do that require running several wires into each door.

I’ve been watching and seen where a couple of members drilled holes in the plugs and ran wires through the male and female plugs.

I think I have only 4 wires or so going into my doors (2 for speaker & 2 for door ajar warning). Is it possible to cut these 4 wires, totally drill (route) a very large hole in each plug and then splice the wires back but just have them loosely run through the (then) large openings in the plugs? The plugs would then only serve to hold the rubber boot in place and keep the opening to the door jam sealed. Does anyone see problems with doing it that way?

1. Can anything be damaged by drilling holes in these plugs? Or completely gutting the center out?

2. From the kick panel side would it be easy to cut the 4 wires going into the plug, or are they too sealed in the harness to easy separate them?

3. Would it be better to just drill enough holes to run the wires I need and leave the 4 that are there already alone?

I had a plan to buy an extra set of the plugs and “practice” drilling them out before I went tearing the truck apart, but according to my dealer you can’t just buy the plugs. They come as part of the complete harness. $625.29, so practice is out of the question.

$625 is also why I’m asking if anything could be damaged by messing (drilling) with the plugs.

I thought about adding a new rubber boot, but it that doesn’t look easy either since there’s no real room to drill. The only way I figure I could do that is to go from inside the door and drill out toward the front (if there’s room), and from inside the kick panel area toward the outside of the cab.

Any other ideas??

Thanks for making this simple Ford!

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