I have a '92 Bronco and I have quite a few questions about wiring lights.
I just purchased a Carr light bar, 2x 150W K/C daylighter spotlights, 2x 55W K/C 57 series flood lights, and 1x 130W daylighter flood light. I also have 2x 57 series driving lights already wired on my grill guard. I plan on using a marine style switch panel such as the one they sell in Cabela's since i plan on having a switch for the driving lights; one for the spotlights; one for the 130W flood light, which i am pointing backward; and one for each of the 57 series flood lights, which will be aimed at the sides of the truck.
I have wired many lights before, but I have never wanted lights to come on with the stock headlamps, and have just run a wire from the batt. to the switch and then a wire from the switch to the lights, and then grounded the lights. I have never used a relay system. What is the benefit of a relay? I always fuse the lights, and the switches I plan on using are rated at like 25 amps. Should I spend the extra time and money to wire 5 switches with a relay, or is my way fine?
I have already mounted the light bar and the lights and checked them all with a short length of wire and battery to be sure they all work. How do I run the wires into the cab? I plan on running 4 wires from the roof, and one from the grill guard. I plan on only running one 8 guage wire from the battery, possibly to one of those brass through panel battery terminals. The wire I purchased is 14 guage primary wire.
Any suggestions on how to run the wires from the roof to the cab or anything else would be greatly appriecated.
THANKS

 

First off... It is against the Highway traffic laws to run more than 2 Headlamps on a road way unless the 4 lights are part of the original design.

You are best off with a relay as the wire going to the lights would require a large gauge wire to run them directly from the battery
ie:10 gauge wire.

The relay could be actuated by a seperate switch and a 14 or 16 gauge wire.

 

i only run the lights off-road, they aren't meant to be used on highways

 

could i run all four circuits on the roof lights off one relay
would 14 guage wire be too small from the switch to the lights?

 

If you want to wire them like you always have, then that is fine. A relay is good if you are using under sized switches, or are planning to tie them into the keyswitch or the headlights to trigger the lights.

If you are just planning a plain switch panel, and the switches are 25 amps each, then you will be fine running them with no relays. Your single 8 guage wire is a good idea too, but make sure you run a heavy fuse for it right at the battery. Then run out of the fuse with the heavy wire, run it into the cab to a small fuse panel with a seperate fuse for each circuit. Run from each fuse to each switch, and then out to each light. The 14 guage wire should be fine if you don't go over 15 amps for each 14 gauge wire.

I would look at the upper rear corner of the front door and see if you have access to the upper roof area. If so, I guess you can drill a hole in the roof to run the wires. Then run down the rear part of the door trim, underneath the door sill plate, up behind the kick panel, then to the switches.

 

would drilling a hole big enough for 4x 14guage wires leak?
the switch panel I plan on using has fuses built in.
Would a 40amp maxi fuse be enough for the power supply wire?

 

btw the cabelas link in my frist post links to the switches, not one of those automatic little links, this one is legit

 

The wires bundled all together in one large hole probably would leak. I would see if you could find some grommets, and then bore 4 small holes with 4 grommets, one for each wire. With a little clear silicone, it probably would be ok.

 

I'll upload pics tomorrow when i can get some pics in daylight of my lightbar,, would it be possible to drill the hole under the light bar and run the wires above the headliner?
how would that be done?]
also how would i drill the holes? and where would the wires go after going through the sheetmetal? once i get it into the windshield pillar or behind the dash i'm fine doing it

 

The A pillar on both sides will allow a small bundle of wire to run thru it like for amber roof lights shown here.




If this was my truck.

I would use a loom for all those lights and run the wiring out the firewall then run it under the cab along the frame and up the back to the light bar .

 

I caught myself in one of my earlier posts. He has a Bronco. The first thing I would do is pull some of the trim off up around the headliner, and pull the headliner down and investigate what it looks like where you want to put the lightbar

I am assuming you have access to a drill and some drill bits for the holes? A step drill would give you the cleanest hole, but they are kind of expensive.

 

here are some pics, let me know if you need more.
i still am stuck on getting the wire into the cab
PLEASE HELP

 

Sounds like you are afraid to drill a hole in the top and ruin the paint job. Take a deep breath and do it(after you take the headliner loose).