Well, I can't find it now at a quarter after midnight, but a while back some of us were discussing the best way to route wires into the doors. The suggestion was made to run a tube right next to the hinge bar, attaching the wires to the hinge to keep them where they have to be. I tried that, without a formed tube, but found that the 9 wires I ended up running into the drivers door, inside a woven loom, were actually thicker than the remaining space between the hinge and the body when the door shut. You could actually feel resistance from the wire loom getting pinched before the door started squeezing the weatherstripping. After analizing the situation for a while, it appeared to me that the best place to try to make this work would be at the top, above the top hinge assembly, and to drill a sized hole that a flexible vinyl tube could squeeze into in the door post, with an elongated matching hole in the door. This seems to work very well...the vinyl moves a little in the door hole as the door closes, but is held firm in the body hole. There is just enough clearance on the inside to feed the wire bundle up and over the kick panel into the fuseblock area. My only concern is if the vinyl tubing will wear in time where it rubs in and out of the door...
Its the oval elongated hole that it rubs through, and I don't think I could find any grommet or bushing that would fit that right. The minor dim is about 13/16", major something like 1-1/4", so it equates to a pretty big hole if it were round. May have to make some sort of oval bushing from polypro or something if it looks to be a problem...I'm not sure it will be...
