A Pillar Wiring

[Curtsbronco]

Been looking for docs on routing wire up the A pillar with limited success beyond one post (below) so recorded the process.
Hope this helps somebody.

Appreciated the pics provided by Alfredo:
https://www.broncosportforum.com/forum/threads/cargo-basket-evolution-lighting-attached.3244/

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[Bucko]

Nice vid!

 

[Scott_Anderson_]

Been looking for docs on routing wire up the A pillar with limited success beyond one post (below) so recorded the process.
Hope this helps somebody.

Appreciated the pics provided by Alfredo:
https://www.broncosportforum.com/forum/threads/cargo-basket-evolution-lighting-attached.3244/

Thanks for sharing this. Is that brush guard on the Badlands RC?

 

[Curtsbronco]

Thanks for sharing this. Is that brush guard on the Badlands RC?

On the Badlands, it's the Rally Innovations light bar. On our Big Bend (right) I've got the Ford Ranger Lifts nudge bar.

 

[ryan_socal]

Thanks for making this. How did you hide the wires at the top?

 

[Curtsbronco]

Thanks for making this. How did you hide the wires at the top?

KC Wire-hider. Too expensive for what it is, but it has stuck and worked flawlessly since the install. https://a.co/d/j4dcPEC

 

[ryan_socal]

Sorry for being dense.. can you help me understand how that fits?

At the end of your video, it looks like you tucked the power and coax cables under the cover and weather stripping for the roof rack channel. The channel cover looks flush and neat, like OEM. Is the KC wire hider installed at that point? Does it perhaps replace the inboard or outboard weather strip? Or replace the whole channel cover? Did you have to remove the channel cover and/or weather stripping?

My roof rack channel cover on a ‘25 badlands looks different, probably because I’m not quite understanding which part in your video is the wire hider. LOL at “accessory ready”.

Side note for future readers.. careful with the top trim snap insert. It was stubborn as Curt and others pointed out. I broke mine and will have to replace it

 

[Curtsbronco]

Sorry for being dense.. can you help me understand how that fits?

At the end of your video, it looks like you tucked the power and coax cables under the cover and weather stripping for the roof rack channel. The channel cover looks flush and neat, like OEM. Is the KC wire hider installed at that point? Does it perhaps replace the inboard or outboard weather strip? Or replace the whole channel cover? Did you have to remove the channel cover and/or weather stripping?

My roof rack channel cover on a ‘25 badlands looks different, probably because I’m not quite understanding which part in your video is the wire hider. LOL at “accessory ready”.

Side note for future readers.. careful with the top trim snap insert. It was stubborn as Curtis and others pointed out. I broke mine and will have to replace it

Not being dense! I wasn’t real obvious on the rest of the wire routing, and just took a couple of pictures for clarity. Probably should have added a bit at the end of that video. I attached the wire hider to the molding. I was never sure how well or if it could be removed, and I usually opt to go a route that can be undone if necessary (limited holes, permanent mods, etc.).

I’ve got a few more dents, pin stripes, miles and stickers since I did the video, so it all fits - and from a distance looks pretty ok.

I’m sure there are many that would love to know if you can route under that molding. I would.

 

[Dude]

I’m sure there are many that would love to know if you can route under that molding. I would.

you can

https://www.broncosportforum.com/forum/threads/cargo-basket-evolution-lighting-attached.3244/post-54944

https://www.broncosportforum.com/forum/threads/wiring-prep-pack.7912/post-141010

 

[ryan_socal]

Not being dense! I wasn’t real obvious on the rest of the wire routing, and just took a couple of pictures for clarity. Probably should have added a bit at the end of that video. I attached the wire hider to the molding. […]

Oooh I see it now! Thanks a bunch. I will do the same. I‘m also avoiding irreversible mods, for the most part, and I won’t mind having the wire hider sit on top of the OEM trim. Looks great in your installation.

you can

https://www.broncosportforum.com/forum/threads/cargo-basket-evolution-lighting-attached.3244/post-54944

Good point! I saw that too after following the breadcrumb Curt helpfully provided at the top of this thread, but I didn’t see any detail about how Alfredo did that. I suppose I or someone could ask him in that thread.

For now, I’m going with wire hider route since that‘ll be easier to work with long term, avoids leaving a gap in the rain channel weather stripping, and looks good to me.

 

[Trist0n]

For others that attempt this, I actually found it really easy to use a plastic spudger and tuck the wires both under the corner of the windshield and under the weather stripping. Additionally since I run roof lights on both sides, it’s easy to run to the other side of the roof across the top of the windshield. Will depend on your wire gauge of course, I used the smallest I could get away with specifically so I could tuck them. Be realistic with the amp draw requirements

 

[Curtsbronco]

For others that attempt this, I actually found it really easy to use a plastic spudger and tuck the wires both under the corner of the windshield and under the weather stripping. Additionally since I run roof lights on both sides, it’s easy to run to the other side of the roof across the top of the windshield. Will depend on your wire gauge of course, I used the smallest I could get away with specifically so I could tuck them. Be realistic with the amp draw requirements

Nicely done! Wasn't quite an option since I have the light bar, side lights (separate switch) and antenna coax I was trying to run, but the lower gauge wire w/o insulation gives you a cleaner install.

Not gonna lie - kinda suprised by the activity on my 2 year old thread today!

 

[Trist0n]

Nicely done! Wasn't quite an option since I have the light bar, side lights (separate switch) and antenna coax I was trying to run, but the lower gauge wire w/o insulation gives you a cleaner install.

Not gonna lie - kinda suprised by the activity on my 2 year old thread today!

The threads where people actually get creative and some actual mods are my favorite to see activity on!

 

[ryan_socal]

For others that attempt this, I actually found it really easy to use a plastic spudger and tuck the wires both under the corner of the windshield and under the weather stripping. […]

Aha! I see how you got it under the roof channel strip now. Was it hard to pop the wires out through the weather stripping under the roof rack attachment point? Did you seal the weather strip at that point? Looks great, like a pro installation. By the way, I've read countless pages of your posts and very much appreciate all the work you’ve put into sharing things here!

I’m running 14 AWG for my main light bar and 16 AWG for a set of 4 round spots on top. I had a lot of trouble squeezing these thick bois out of the top of the A pillar trim which still doesn’t sit perfectly flush at the top. Tried tucking them under the corner of the windshield but they didn’t fit.

[…] Not gonna lie - kinda suprised by the activity on my 2 year old thread today!

I hope you don’t mind. Since you cleared up the question of how you routed along the roof trim, maybe we should stop here and not grow this into an uber thread about all possible solutions. It’s just.. you did a great job with the video and crediting Alfredo’s prior work.

Another by-the-way.. Rally Innovations wasn’t on my radar for BS stuff until you mentioned your front bumper light bar.

 

[Curtsbronco]

I hope you don’t mind. Since you cleared up the question of how you routed along the roof trim, maybe we should stop here and not grow this into an uber thread about all possible solutions. It’s just.. you did a great job with the video and crediting Alfredo’s prior work.

Another by-the-way.. Rally Innovations wasn’t on my radar for BS stuff until you mentioned your front bumper light bar. I reached out to them about R&D for a similar bar to fit the new ‘25 badlands steel bumper and will be working with them soon.

Not at all! I'm glad it's been useful. The youtube video increments viewers periodically, but not a lot of feedback, so never know.

Rally Innovations has been one of the few 3rd parties to actually do much for the Sports, so glad they are still pursuing it. Hope you enjoy your '25.... they've got some nice adds. I really like that new Desert Sand color, but not enough to make a change.

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