Roof rack lights, how'd you run your wires?

[odinskind]

I'm going to wire up my roof rack this weekend and was curious how others have done it. 40" led bar up front, 4 side lights, and rear backup lights.

 

[linuxgod]

I have a bluesea breaker that runs to a bluesea fuse box. I ran two pairs of 14ga wire inside a 3/8" plastic wire loom out the engine bay and up the C channel in the windshield on the passenger side. All my connectors are DT, which are supposedly weatherproof, but I used heat shrink and 3M Super-88 tape to be sure. I just put some black RTV in the C channel and the 3/8" wire loom fit in there snugly. On the roof I used UV-stable high strength zip ties, since the cheapo ones will degrade and break over time in the sun.

Make sure any wire you use is automotive grade. SXL/GXL/etc. I have a post around here somewhere with a few photos of the install, but if you need more advice I can take photos and post my materials.

 

[odinskind]

I have a bluesea breaker that runs to a bluesea fuse box. I ran two pairs of 14ga wire inside a 3/8" plastic wire loom out the engine bay and up the C channel in the windshield on the passenger side. All my connectors are DT, which are supposedly weatherproof, but I used heat shrink and 3M Super-88 tape to be sure. I just put some black RTV in the C channel and the 3/8" wire loom fit in there snugly. On the roof I used UV-stable high strength zip ties, since the cheapo ones will degrade and break over time in the sun.

Make sure any wire you use is automotive grade. SXL/GXL/etc. I have a post around here somewhere with a few photos of the install, but if you need more advice I can take photos and post my materials.

I'm interested in the penetration from the engine bay to the a pillar. If you could provide me a link to your previous post I'd greatly appreciate it. Or if you could take close up shots of the penetration and the "ride" up the A pillar, that would be helpful too.

 

[linuxgod]

Only thing I can't find is the battery cable I used. I think this is everything else:

Air On Board switches I used for front LED light bar and rear camp lights:

Push switch 907G 12volt Toyota OEM Replacement LED LIGHT BAR green SW907G 1
Wire Plug 1 x Wire Plug $0.00 SW800WP
Switch Body 1 x LED GREEN $0.00 SW9W00GBN
Switch Cover 1 x LED LIGHT BAR $0.00 SW907CVN

Push switch 9B04G 12volt Toyota OEM Replacement REAR LIGHTS green SW9B04G 1
Wire Plug 1 x Wire Plug $0.00 SW800WP
Switch Body 1 x LED GREEN $0.00 SW9W00GBN
Switch Cover 1 x REAR LIGHTS $0.00 SW9B04CVN

14ga wire I ran up to the roof. I bought this from wirebarn.com:

Item # Description Qty
14-GXL-RED-100F RED 14 Gage GXL Wire 1
14-GXL-BLACK-100F BLACK 14 Gage GXL Wire 1
STDFUSE-5A-5 Standard ATO ATC STYLE 5 AMP Automotive Fuse (Tan Color) - 5 Pack 1

Blue Sea Fuse Block 12 circuit with negative from Amazon
Amazon.com : Blue Sea Systems ST Blade Fuse Block - 12 Circuits with Negative Bus & Cover : Fuse Block With Relay : Sports & Outdoors

Hammond ABS box from Amazon (which I mounted the fuse block inside to help protect from water):
Hammond 1591ESBK ABS Project Box, Black - Electrical Boxes - Amazon.com

3/8" wire loom (though you don't need anywhere near 100')
Amazon.com: Absolute USA SLT38 3/8-Inch x 100-Feet Split Loom Tube: Car Electronics

DT connectors and the crimp ends from mouser.com:
Line
No. Mouser Part Number
Customer Part Number
Manufacturer Part Number
Description Quantity Ordered Quantity Shipped
1

1
654-AT06-2S-BLK
MFG Part No:AT06-2S-BLK
AT06-2S-BLK
Amphenol Automotive Connectors
US HTS:8536694051 ECCN:EAR99 COO:CN 8 8
2

1
654-AT04-2P-BLK
MFG Part No:AT04-2P-BLK
AT04-2P-BLK
Amphenol Automotive Connectors
US HTS:8536694051 ECCN:EAR99 COO:CN 10 10
3

1
654-AW2P
MFG Part No:AW2P
AW2P
Amphenol Automotive Connectors
US HTS:8535908040 ECCN:EAR99 COO:CN 10 10
4

1
654-AW2S
MFG Part No:AW2S
AW2S
Amphenol Automotive Connectors
US HTS:8535908040 ECCN:EAR99 COO:CN 8 8
5

1
654-AT60-14-0122
MFG Part No:AT60-14-0122
AT60-14-0122
Amphenol Automotive Connectors
US HTS:8535908040 ECCN:EAR99 COO:CN 20 20
6

1
654-AT62-14-0122
MFG Part No:AT62-14-0122
AT62-14-0122
Amphenol Automotive Connectors
US HTS:8535908040 ECCN:EAR99 COO:US 16 16
1RoHS: Compliant

 

[ethernectar]

My install starts about here on my build thread: XPLOR R - 2014 200 Series Build

 

[linuxgod]

I'm interested in the penetration from the engine bay to the a pillar. If you could provide me a link to your previous post I'd greatly appreciate it. Or if you could take close up shots of the penetration and the "ride" up the A pillar, that would be helpful too.

I'll take a photo, but I basically just notched the black plastic at the bottom with an exacto knife to fit the loom and then used some RTV to seal the gap (though I think that's unnecessary really). I probably could have skipped cutting it but the hood would have crushed the plastic loom.

This thread has a lot of the details though not the actual pic I know I have but am looking for:

What have you done to your 200 Series this week?

 

[linuxgod]

A little blurry but here's a photo which shows the spot I notched.

 

[odinskind]

A little blurry but here's a photo which shows the spot I notched.

View attachment 1461934[/QUOTE

Thanks for the info! Definitely will come in handy this weekend.