Roof Rack Lightbar Wire Routing

Hey everyone,

Haven't seen anything here that specifically mentions routing wires from under the hood to lights/accessories on a roof rack. I had some success rewiring my roof rack lights yesterday so I'll share what I learned and hopefully help someone else in a similar position.

I need to run 4 wires (2 hot, 2 ground) for my setup consisting of a 42" light bar and 360 down lighting. Previously I unsuccessfully tried to tuck my too-large wire bundle under the windshield gutter, so this time around I began with slimness in mind.

I started some bonded 16ga 4-wire trailer wire from Home Depot and wrapped that in 5/8" 3:1 heat shrink for protection. Routing from under the hood, through the grommet in the windshield boot, and tucked that bonded 4-wire vertically into the crack on the OUTSIDE of the windshield gutter using a deadblow hammer and a piece of cardboard to tap it in place.

The fit is super tight and did not require any adhesive. It's nearly invisible except at the top where it pops out to go under the roof rack's fairing. I think this is a pretty solid method for routing roof rack wiring.

@CaliRaisedLed 42" light bar
@victory4x4 roof rack and 270 degree down lighting

 

Hey man I know this is an old thread, but your wiring job looks great. Where did you get heat shrink sheathing long enough for the entire length of the windshield?

 

You can buy rolls of heat shrink. Just put 5/8 heat shrink into Amazon search. However, how does heat shrink hold up to long term sun exposure? That would be my concern. Maybe they make it in a UV resistant material. @skeletron how's this look today?

 

Yep I got the heat shrink on Amazon and the trailer wire from home depot I think. Still looks and functions perfectly today