Wire Routing Strategy — Trader-01¶

Vehicle: 1996 F-250 Crew Cab System: Infinitybox NGX Status: In Progress Last Updated: 2026-02-01

Routing Philosophy¶

Run wires once, run them right. Every wire should: - Follow factory routing paths where possible - Stay away from heat sources (exhaust, engine) - Be protected from abrasion and pinch points - Be accessible for future service - Use appropriate connectors at junction points

Key Principle: POWERCELLs close to loads = shorter high-current runs. MASTERCELL close to switches = shorter signal runs.

Vehicle Layout Reference¶

                    FRONT
    ┌─────────────────────────────────────────┐
    │            ENGINE BAY                    │
    │  ┌─────┐                      ┌─────┐   │
    │  │BATT │    [ENGINE]          │FRONT│   │
    │  │     │                      │ PC  │   │
    │  └─────┘                      └─────┘   │
    │         ════════════════════            │
    │              FIREWALL                   │
    ├─────────────────────────────────────────┤
    │              CAB                         │
    │  ┌─────┐  ┌───────┐  ┌─────┐           │
    │  │MSTR │  │CLUSTER│  │SWITCH│           │
    │  │CELL │  │       │  │PANEL│           │
    │  └─────┘  └───────┘  └─────┘           │
    │    [DRIVER]      [PASS]                 │
    │    [REAR L]      [REAR R]               │
    ├─────────────────────────────────────────┤
    │           BEHIND CAB                    │
    │              ┌─────┐                    │
    │              │REAR │                    │
    │              │ PC  │                    │
    │              └─────┘                    │
    │                                         │
    │             [FUEL TANK]                 │
    │                                         │
    │         ┌─────────────────┐             │
    │         │   TAIL LIGHTS   │             │
    └─────────┴─────────────────┴─────────────┘
                    REAR

Zone 1: Engine Bay¶

Battery Location¶

Position: Driver side, OEM location Upgrades: Consider relocation to inner fender for cleaner runs (optional)

Front POWERCELL Location¶

Recommended: Driver inner fender, forward of wheel well

Criteria	Driver Fender	Pass Fender	Firewall
Heat exposure	Moderate	Lower	Higher
Water exposure	Fender spray	Fender spray	Protected
Wire run to battery	Short	Long	Medium
Wire run to lights	Medium	Medium	Long
Accessibility	Good	Good	Poor

Mounting considerations: - Keep above wheel well splash zone - Angle slightly for water runoff - Use vibration-isolating mounts - Ensure CAN cable reaches through firewall

Engine Bay Wire Runs¶

BATTERY (+)
    │
    ├──[4 AWG]──► FRONT POWERCELL (main feed, fused at battery)
    │
    ├──[8 AWG]──► STU CONTROL PACK (fused at battery)
    │
    ├──[0 AWG]──► STARTER RELAY (unfused, direct)
    │
    └──[4 AWG]──► REAR RUN (to rear POWERCELL, fused)

BATTERY (-)
    │
    ├──[0 AWG]──► ENGINE BLOCK (primary ground)
    │
    ├──[4 AWG]──► FRAME (chassis ground)
    │
    └──[4 AWG]──► FRONT POWERCELL (cell ground)

Front Lighting Runs¶

From Front POWERCELL to lights:

Circuit	Route	Length Est.	Protection
Low Beam L	Fender → headlight bucket	3 ft	Loom
Low Beam R	Across core support → R bucket	6 ft	Loom
High Beam L	With low beam	3 ft	Loom
High Beam R	With high beam	6 ft	Loom
Parking L	Fender → marker	2 ft	Loom
Parking R	Across core support → R marker	5 ft	Loom
Turn Front L	Fender → turn housing	3 ft	Loom
Turn Front R	Across → R turn housing	6 ft	Loom
Horn	To horn(s) on core support	4 ft	Loom

Cross-radiator runs: Bundle together, use split loom, secure to core support or radiator shroud (avoid hot spots).

Zone 2: Firewall Penetration¶

Primary Pass-Through Location¶

Recommended: Driver side, reuse OEM grommet location or drill new

OEM locations on 1996 F-250: - Main harness grommet (driver side, large) - HVAC hose pass-through (center) - Heater core lines (passenger side)

What Goes Through Firewall¶

Wire/Cable	Gauge	Direction	Notes
CAN bus (to MASTERCELL)	18 AWG shielded	Engine → Cab	Twisted pair + shield
Key-on signal	18 AWG	Cab → Engine	To STU, front PC
Crank signal	18 AWG	Cab → Engine	To starter relay
Tach signal	18 AWG	Engine → Cab	STU to cluster
Reverse signal	18 AWG	Engine → Cab	STU to MASTERCELL
Gauge signals	18-22 AWG	Engine → Cab	Temp, oil, etc.
HVAC control	TBD	Cab → Engine	If electric A/C clutch

Estimated total conductors: 12-16 wires through firewall

Grommet Strategy¶

Option	Pros	Cons
Bulk rubber grommet	Cheap, easy, seals well	Harder to add wires later
Pass-through bulkhead	Organized, expandable	More expensive, larger hole
Deutsch bulkhead	Weatherproof, serviceable	Limited pin count per connector
Reuse OEM grommet	No drilling	May be deteriorated, limited space

Recommendation: Bulk grommet for main pass, with wires bundled in split loom on both sides.

Zone 3: Interior (Cab)¶

MASTERCELL Location¶

Options:

Location	Pros	Cons
Under dash (driver)	Close to switches, easy access	Knee space, visible
Under dash (center)	Central to all runs	HVAC in the way
Behind kick panel	Hidden, protected	Longer switch runs
Under driver seat	Hidden, accessible	Long runs, seat track interference
Behind rear seat	Crew cab = lots of space	Long runs to everything

Recommendation: Under dash, driver side kick panel area — short runs to column switches and dash switches, easy firewall pass-through access.

Interior Wire Runs¶

MASTERCELL (under dash, driver side)
    │
    ├──► Column switches (turn, wiper, key)     [1-2 ft, behind column]
    │
    ├──► Dash switches (headlight, hazard)      [2-3 ft, behind dash]
    │
    ├──► Aux switch panel (console)             [3-4 ft, under carpet/console]
    │
    ├──► Gauge cluster                          [2-3 ft, behind dash]
    │
    ├──► Door jamb switches (4 doors)           [varies, see door routing]
    │
    ├──► Brake pedal switch                     [1-2 ft, direct]
    │
    ├──► Parking brake switch                   [2-3 ft, to console/floor]
    │
    └──► CAN bus to rear                        [10-12 ft, under carpet]

Routing Paths Inside Cab¶

Under-carpet runs: - Driver side: MASTERCELL → rear, along rocker panel - Center tunnel: TC controller wires, console power - Passenger side: Minimal runs, door triggers only

Behind dash: - Use OEM harness channels where possible - Zip-tie to existing harness or brackets - Keep away from HVAC ducting

Zone 4: Door Wiring¶

inMOTION Cell Locations¶

Each door gets one inMOTION cell mounted inside the door.

Door	Cell Address	Functions
Driver Front	3	Windows (all 4 from master), locks, mirror, puddle
Passenger Front	4	Window, lock, puddle
Driver Rear	5	Window, lock (child lock input), puddle
Passenger Rear	6	Window, lock (child lock input), puddle

Door-to-Body Wiring¶

Critical consideration: Door wiring flexes thousands of times over vehicle life. Must use: - Flexible wire (GXL or TXL, not GPT) - Proper door boot/grommet - Strain relief at both ends - Service loop inside door

Wires through each front door jamb:

Wire	Gauge	Purpose
CAN High	18 AWG	inMOTION communication
CAN Low	18 AWG	inMOTION communication
+12V (constant)	12 AWG	Power to inMOTION
Ground	12 AWG	inMOTION ground
Door ajar	18 AWG	To MASTERCELL (if not through inMOTION)

Total: 5-6 wires per door (vs. 15+ wires in conventional system)

Door Boot Routing¶

     BODY SIDE              DOOR SIDE
    ┌─────────┐            ┌─────────┐
    │         │            │         │
    │  B-pillar            │  Door   │
    │  or A-pillar         │  hinge  │
    │         │            │  area   │
    │    ═════╪════════════╪═════    │  ← Flexible boot
    │         │            │         │
    └─────────┘            └─────────┘

OEM boot location: Between door and A-pillar (front) or B-pillar (rear)

Zone 5: Rear of Vehicle¶

Rear POWERCELL Location¶

Recommended: Behind cab, under rear seat or in cab corner (crew cab)

Why crew cab helps: Extra cab space means rear POWERCELL can mount inside cab, protected from elements.

Location	Pros	Cons
Behind rear seat	Protected, accessible	Run from engine bay longer
Under bed (forward)	Short to tail lights	Weather exposure
In-bed toolbox	Protected	Dedicated space needed
Frame rail	Short runs	Full weather exposure

Rear POWERCELL Runs¶

REAR POWERCELL (behind rear seat)
    │
    ├──[4 AWG]──► Battery (power feed, from front run)
    │
    ├──[4 AWG]──► Ground (to frame or battery neg)
    │
    ├──[CAN]────► MASTERCELL (from front, daisy-chain)
    │
    └──► OUTPUTS:
         ├── Tail lights L/R      [6-8 ft, down B-pillar, along frame]
         ├── Brake lights         [with tail lights]
         ├── Turn rear L/R        [with tail lights]
         ├── Reverse lights       [with tail lights]
         ├── License plate light  [with tail lights]
         ├── 3rd brake light      [up B-pillar, across headliner]
         ├── Fuel pump            [under cab, to tank]
         └── Dome/cargo lights    [short, in cab]

Tail Light Routing¶

Path: Rear POWERCELL → down B-pillar → under cab → along frame rail → up into bed side → tail light housing

Bundle strategy: All rear lights share same path, split at each tail light housing

Wire	Destination
Brown	Tail/marker
Green	Brake
Yellow	Turn L
Green/Yellow	Turn R
White	Reverse
Black	Ground (star at tail light)

Fuel Pump Run¶

Path: Rear POWERCELL → under cab floor → to fuel pump connector at tank

Use OEM fuel pump connector if available
14 AWG minimum for pump current
Include ground wire (don't rely on tank strap)

Zone 6: CAN Bus Backbone¶

CAN Network Topology¶

Infinitybox uses a daisy-chain CAN topology:

MASTERCELL ──CAN──► FRONT PC ──CAN──► REAR PC
                        │
                        └──CAN──► inMOTION cells (branch)

CAN Cable Requirements¶

Wire type: Twisted pair, shielded (or Infinitybox supplied cable)
Gauge: 18-22 AWG typical
Shield: Drain wire to ground at one end only (MASTERCELL)
Max length: ~40 meters total (not a concern for single vehicle)

CAN Routing Path¶

MASTERCELL (under dash)
    │
    │ [2 ft] through firewall
    ▼
FRONT POWERCELL (engine bay)
    │
    │ [12 ft] under cab, along frame/rocker
    ▼
REAR POWERCELL (behind seat)
    │
    │ [branches to each door]
    ├──► inMOTION Driver Front [through A-pillar]
    ├──► inMOTION Pass Front [through dash, across, down A-pillar]
    ├──► inMOTION Driver Rear [down B-pillar]
    └──► inMOTION Rear Pass [across rear, down B-pillar]

CAN Termination¶

MASTERCELL has internal termination
Last device in chain needs 120Ω terminator (check Infinitybox docs)
Unterminated CAN = communication errors

Wire Protection Methods¶

Location	Protection	Notes
Engine bay	Split loom + tape	Heat-resistant loom near exhaust
Firewall pass	Grommet + sealant	Prevent water intrusion
Under carpet	Loom or lay flat	Protect from seat tracks
Door jamb	Flexible boot + loom	Must flex without fatigue
Under cab/frame	Hard conduit or loom	Protect from road debris
Bed area	Conduit in stake pockets	Protect from cargo

Connector Strategy¶

Location	Connector Type	Why
POWERCELL pigtails	Infinitybox supplied	Match harness
Light connections	Weatherpack or OEM	Serviceable, waterproof
Door pass-through	Deutsch DT	Waterproof, compact
Switch panel	Deutsch DT or Molex	Serviceable
Firewall bulkhead	Bulk grommet	Simplicity
Fuel pump	OEM connector	Proven fit

Grounding Strategy¶

Ground Locations¶

Ground Point	Connected Loads	Wire Gauge	Location
Battery negative	Primary system	0 AWG	Battery post
Engine block	Alternator, sensors	2 AWG	Block to frame
Front frame	Front POWERCELL	4 AWG	Frame rail near battery
Firewall	MASTERCELL	10 AWG	Existing OEM ground point
Rear frame	Rear POWERCELL, fuel pump	4 AWG	Frame rail under cab
Each tail light	Tail light grounds	16 AWG	Housing or bed bolt
Each door	inMOTION ground	12 AWG	Door hinge or dedicated

Star Grounding¶

For best results, critical grounds should "star" back to battery negative:

                    BATTERY (-)
                        │
        ┌───────────────┼───────────────┐
        │               │               │
    ENGINE          FRONT PC        REAR PC
    BLOCK           GROUND          GROUND
        │
      FRAME

Wire Lengths Estimate¶

Power Cables (Battery to Devices)¶

Run	Gauge	Length	Fuse
Battery → Front POWERCELL	4 AWG	3 ft	150A at battery
Battery → STU Control Pack	8 AWG	4 ft	60A at battery
Battery → Starter	0 AWG	3 ft	None (direct)
Battery → Rear POWERCELL	4 AWG	15 ft	100A at battery

Signal Cables (MASTERCELL to Inputs)¶

Run	Gauge	Length
MASTERCELL → Column switches	18 AWG	2 ft
MASTERCELL → Dash switches	18 AWG	3 ft
MASTERCELL → Aux panel	18 AWG	4 ft
MASTERCELL → Brake switch	18 AWG	2 ft
MASTERCELL → Door triggers (avg)	18 AWG	6 ft each

CAN Bus¶

Segment	Length
MASTERCELL → Front PC	3 ft
Front PC → Rear PC	12 ft
Rear PC → inMOTION branches	3-6 ft each

Installation Sequence¶

Recommended order for wire installation:

Battery cables first — main power backbone
CAN bus backbone — MASTERCELL to all cells
Front POWERCELL outputs — engine bay lighting
Firewall pass-through — all cab-to-engine wires
MASTERCELL inputs — switch wiring inside cab
Rear POWERCELL run — power and CAN to rear
Rear POWERCELL outputs — tail lights, fuel pump
Door wiring — inMOTION cells last (doors off easier)
Final grounds — verify all ground points solid
Test and label — verify every circuit, label both ends

Documentation Needed¶

Before starting installation:

Photos of existing wire routing paths
Measurements: firewall to each light
Measurements: battery to POWERCELL locations
Measurements: MASTERCELL location to switch locations
OEM grommet locations and sizes
Frame rail access points

Open Questions¶

Question	Impact	Notes
Rear POWERCELL inside cab or under bed?	Run lengths, protection	Crew cab favors in-cab
Reuse OEM firewall grommet or drill new?	Installation effort	Check OEM grommet condition
Door boot style	Purchase decision	OEM or universal?

Parts for Wire Routing¶

Item	Qty	Notes
Split loom (1/2")	50 ft	Engine bay, under cab
Split loom (1/4")	50 ft	Signal wires
Heat shrink (assorted)	Kit	Connections
Rubber grommet (1.5")	2	Firewall, floor
Door boots	4	OEM style or universal
Wire ties (assorted)	100+	Everywhere
Adhesive tie mounts	50	Inside cab, clean mounting
P-clamps (assorted)	20	Frame rail mounting
Conduit (1")	20 ft	Under-cab runs

MASTERCELL_INPUT_MAP.md — what connects to MASTERCELL
POWERCELL_OUTPUT_MAP.md — what connects to POWERCELLs
SWITCH_PANEL_LAYOUT.md — switch locations
ELECTRICAL_PLANNING.md — system overview