Drilling Out the ‘Trail Rated’ Badge for External 120V Inlet?

[ChrisNLA]

I installed my Noco plug in the rear bumper, but I typically back into my parking spot at the house.

That makes me wonder if a Kussmaul or similar auto-ejector like what is on emergency vehicles could be retrofitted to the bumper

The Super Auto Eject might fit in the rear bumper near where mine is. Not sure about the front. Its waterproof though so it doesnt have to be completely hidden away.

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[NotSo Bright White]

I velcroed the Naco to my battery cover and zip tied the cord so it fell just below the fender liner in both Gladiators. It takes a few seconds to plug/unplug it and I didn’t have to drill or alter anything permanently. Yes, I have driven off with it plugged in but the tire rolls over it and unplugs it. An unintentional consequence that has been tested more than once.

 

[Capngeo]

so IF you are going thru the body sheetmetal get one of these knock out punch sets or if you have a buddy who is an electrician, he should have one too

 

[Bandit’s Lair]

so IF you are going thru the body sheetmetal get one of these knock out punch sets or if you have a buddy who is an electrician, he should have one too

Those work well. I was skeptical that it’d make a clean cut at first but after using it it did the job at a fraction of the price of a more mainstream branded set.

 

[JoeJeep74]

I don’t know how to link , but I posted pictures and “how to “ directions on here when I installed NOCO onboard charger and plug. Plug is installed in front lower bumper/air deflector plastic panel. Out of site and if you back out of garage power cord will pull out( power cord is tied down). My .02 cents and I apologize for not being able to link.

 

[BogBeaver]

so IF you are going thru the body sheetmetal get one of these knock out punch sets or if you have a buddy who is an electrician, he should have one too

I was just planning on putting a 2x4 behind the panel to have something to drill into with a 2” hole saw. Are these punches that much better?

I don’t know how to link , but I posted pictures and “how to “ directions on here when I installed NOCO onboard charger and plug. Plug is installed in front lower bumper/air deflector plastic panel. Out of site and if you back out of garage power cord will pull out( power cord is tied down). My .02 cents and I apologize for not being able to link.

Any corrosion issues on the plug here? I’m sure the rubber cover is decent but I’m not sure I have that much faith in it.

I installed my Noco plug in the rear bumper, but I typically back into my parking spot at the house.

I will say that looks pretty good. It does seem like a long way to route the extension cord up to the engine bay though. I can also guarantee I’d forget I have it plugged in and take off…. I figure it’d be hard to miss if it’s right beside the driver’s side door.

 

[BogBeaver]

An update for everyone

I attempted to remove my antenna to see how deep the area behind that hole is. Found this video that shows a guy sticking his whole finger straight in so I figured I’d take a look at my antenna side. I couldn’t get the antenna mount cover to pop off so I decided to see if I could pull the fender panel off far enough to see if there is a hole behind the Trail Rated badge on the driver’s side.

I was able to pull the cowl off and a few additional bolts to get a slight view of the backside of the fender panel. There is a hole in the next panel back like shown in the repair manual and it is at least an inch and a half deep. Only way I could measure was by using a long Allen key to be able to reach in there and stick the other end into the hole so take that measurement with a grain of salt.

I’m gonna go ahead with my original plan and try to remove the fender panel to take a better look before fully committing. It doesn’t look too involved to pull that panel off. Will update with photos when I get that done and hopefully provide measurements for anyone in the future.

 

[Capngeo]

Yes the punch leaves a much cleaner hole than a hole saw does.

 

[JoeJeep74]

I was just planning on putting a 2x4 behind the panel to have something to drill into with a 2” hole saw. Are these punches that much better?




Any corrosion issues on the plug here? I’m sure the rubber cover is decent but I’m not sure I have that much faith in it.




I will say that looks pretty good. It does seem like a long way to route the extension cord up to the engine bay though. I can also guarantee I’d forget I have it plugged in and take off…. I figure it’d be hard to miss if it’s right beside the driver’s side door.

I was just planning on putting a 2x4 behind the panel to have something to drill into with a 2” hole saw. Are these punches that much better?




Any corrosion issues on the plug here? I’m sure the rubber cover is decent but I’m not sure I have that much faith in it.




I will say that looks pretty good. It does seem like a long way to route the extension cord up to the engine bay though. I can also guarantee I’d forget I have it plugged in and take off…. I figure it’d be hard to miss if it’s right beside the driver’s side door.

I don’t see any corrosion. The rubber plug is still fitting well and as the plug is angled down somewhat snow/water run off as opposed to pooling.

 

[Jaxmax]

The punches are much better but for most part they are sized for electrical knockout holes, and everything punch or hole saw, starts with a 1/4" round hole, that oblong hole that locates the badge will need to be a concern, using a hole saw might walk from center and really make a mess of your fender. You should not have to put a 2X4 behind the hole just get a fine tooth hole saw ,go slow at first and don't push, let the tool do the work. Whatever you do when plugging in always hang the cord over your mirror, or better yet a soft hook on the door handle, you will drive away plugged in sometime, and every year ya get older it has a better chance of happening! I still like the cord in the rear bumper opposite side from trailer plug. Tape up the cord ends when installing and good luck, post pictures!.....Jack

 

[Capngeo]

The punches are much better but for most part they are sized for electrical knockout holes, and everything punch or hole saw, starts with a 1/4" round hole, that oblong hole that locates the badge will need to be a concern, using a hole saw might walk from center and really make a mess of your fender. You should not have to put a 2X4 behind the hole just get a fine tooth hole saw ,go slow at first and don't push, let the tool do the work.

The punch set I have goes from ⅞" to1" by 1/8ths then to 4" by quarters

Whatever you do when plugging in always hang the cord over your mirror, or better yet a soft hook on the door handle, you will drive away plugged in sometime, and every year ya get older it has a better chance of happening!

I feel your pain there; I can't remember bugger-all anymore! Kussmaul makes some cool stuff for that... It was what we had in the FD

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