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Old 04-10-2009, 06:05 PM   #1
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off road lights and light bar

ok so i purchased 4 7'' lights to go on my light bar and installed them had to cut and splice and all that good stuff to get them installed with the wiring inside the light bar. the stock switch's that came with each pair were horrible and intermittently worked. so i wanted to wire it to one switch, i got a 50amp switch so that has enough power, then where i spliced the 2 sets of lights to the switch i have 10gauge wiring. and 30amp fuses in the fuse slots. but its still burning up, any suggestions?

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Old 04-10-2009, 06:07 PM   #2
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Dont wire it up with only a switch. Use a switch and a relay.

Sorry it´s in German...


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Old 04-10-2009, 06:26 PM   #3
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X2 but even then I would say go with two relays(one for each set of lights)with separate feeds to the relay but one common feed to the switch so they all come on with one switch.That way you will only pull very little amps to trigger the relays but then the relays pull the heavy load from two separate sources!!!!
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Old 04-10-2009, 06:29 PM   #4
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each pair of lights has its own relay already, i think they are all wired with 16g wire tho, 16 or 18 idk. should i try to rewire it all with 10g? since i want all 4 lights on a single switch
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Old 04-10-2009, 06:33 PM   #5
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Are that 100W bulbs? Then you should use at least 3-4 mm˛ wire for every pair. don´t know how thick 10 gauge wire is. Here´s a list: American wire gauge - Wikipedia, the free encyclopedia
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Old 04-10-2009, 06:34 PM   #6
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they are 55watts each
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Old 04-10-2009, 06:36 PM   #7
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Then 2-2.5 mm˛ wire is ok for every pair.
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Old 04-10-2009, 06:48 PM   #8
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Do you have it wired like this and what is melting down the wire or the switch???? If it is the switch you have something wired wrong because you should only be using the switch to trigger the relay and that is very little current.If it is the main feed wire going to the relay and or the wires going to the lights then yes you will have to go heavier.(sorry for stealing your pic nico)
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Old 04-10-2009, 09:27 PM   #9
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i will check it just to check my buddy helped me install it so i will get back to you with exactly how it is and possibly pictures so you can see it.
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Old 04-10-2009, 09:28 PM   #10
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i have 2 seperate relays that are not connecting the 2 light sets, only 1 light set per relay
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Old 04-10-2009, 11:45 PM   #11
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what is burning up?
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Old 04-11-2009, 12:22 AM   #12
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here are some pics
the lights


wiring getting pushed behind the dash

direct from the lights to the relay than to the switch and the battery through the grommet on the drivers side.

the 2 original switch wires now spliced together, they were burning up at the yellow butt connectors.

coming out of the drivers side under the hood.

connected to the battery of course with fuses out. i had to jump from the 15amp original fuses to 30amp now.
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"going topless"
Roads? Where were going we dont need roads.
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Old 04-11-2009, 12:42 AM   #13
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start with checking all your connections. loose conections generate heat. when did the wires burn? how long were they on b4 the conn burnt? were u driving or sitting stilll? if the kit recomends 15amp fuses it should work w/ 15s
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Old 04-11-2009, 12:47 AM   #14
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we just put in the fuses when it started to burn at the yellow butt connectors, so standing still. we were trying 15amp fuses and they would pop if they looked at the ports. so we put in 30s and they dont pop. and i did notice the wiring at the yellow connectors is about 18 gauge so i might have it replace that with 10 gauge
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Old 04-11-2009, 01:15 AM   #15
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how many amps is the system rated at? 18 to 10 is a prety big jump. what did the system come with?
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Old 04-11-2009, 01:24 AM   #16
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what we are trying to do is wire 2 separate systems together, so all 4 lights are controlled by a single switch, they were 15 amp single but now that they are connected it increased the ampherage to 30
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Old 04-11-2009, 01:30 AM   #17
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but from what your pics look like, each system is hooked up to power seperately, and they only hook together at the switch, so it should still only pull 15.
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Old 04-11-2009, 01:41 AM   #18
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at the switch they are connected putting 30 through the switch wiring. but the 30 stops at the relay. so now i will have to just replace that wiring for the switch with the 10g and it should be good right?
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31'' BFG A/T
4.0L I-6 5SPD Man
"going topless"
Roads? Where were going we dont need roads.
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Old 04-11-2009, 01:59 AM   #19
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should be. u said its a 50a switch right? is that what the yellow conns were for the switch to the rest of the system?
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Old 04-11-2009, 02:02 AM   #20
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yes the yellow connectors next stop was the 50a switch
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31'' BFG A/T
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"going topless"
Roads? Where were going we dont need roads.
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Old 04-11-2009, 02:04 AM   #21
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make sure the conection is TIGHT. the switch should b fine
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Old 04-11-2009, 02:06 AM   #22
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yea im going to replace that wire tomorrow morning, its 1am here ... well this morning. with a name like pyro im not sure i want to trust yoru electrical work lol dont want to burn my house down..
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"going topless"
Roads? Where were going we dont need roads.
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Old 04-11-2009, 02:13 AM   #23
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its ok Im a fireman. I was an electrician b4 that
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Old 04-11-2009, 02:17 AM   #24
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youll come to TX and put out my houseand jeep?
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2000 Jeep Wrangler Sahara TJ
S&B Cold Air Intake
31'' BFG A/T
4.0L I-6 5SPD Man
"going topless"
Roads? Where were going we dont need roads.
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Old 04-11-2009, 02:37 AM   #25
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if theres fire, I will come
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Old 04-16-2009, 10:39 PM   #26
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did u ever figure this out? Im looking at light bars now and wanted to get your input. what kind do u have? where did u get it? do u like it?

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