What Wire Gauge?

[PrepVet]

What gauge wire are you using to wire in LED pod lights and the upfitter switches?

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[Squirrel13]

Gauge is dependent on ampacity and distance. Unless you’re trying to run a 50” light bar 16 or 18g. should be fine. If you have a longer run maybe 14g. The bigger issue is to use a TXL or GXL wire.

 

[iamcris]

This book is for tractor/trailers but the theory applies. Hope this helps.

 

[NC_Oak]

wire size is based on the load (and type of load, resistive v inductive) and fuse is based on the wire size. Heat becomes a factor first when you're undersized. I do a lot of machine and process control systems if you REALLY want to be sure, post up your lights and we can tell you what's best.

 

[box986]

relays are always the way to go when wiring exterior lighting

 

[NC_Oak]

relays are always the way to go when wiring exterior lighting

relays are always the way to go when you have a decent size load and want to switch it smartly with just a little current. I would say exterior v interior doesnt matter.

totally agree tho. little rocker switches in the cab should be run to relay coils for any substantial load. again, sizing is what we need to know

 

[ORACLE Lighting]

Depends on the wattage of the lights, the current (and distance from the power source) will determine the necessary cable size.

 

[CalvinT]

Gauge is dependent on ampacity and distance. Unless you’re trying to run a 50” light bar 16 or 18g. should be fine. If you have a longer run maybe 14g. The bigger issue is to use a TXL or GXL wire.

Just make sure to note the current requirements. Depending on which model you're looking at a 40" light bar can draw anywhere from 16 to 29 amps.

 

[CalvinT]

TXL or GXL wire.

TXL and GXL wire insulations are rated for 125C, the wire you find in most stores is rated for 85C unless specified otherwise. Both TXL and GXL will cost more.

 

[CalvinT]

I've done a lot of research and thinking. I've decided SW 1 and 2 are good for 15 amps. Both have the same size wire. The remaining switches are good for 6 amps. This is assuming continuous loads such as lights. You can go up to Ford's rating for SW 3-6 if it's a short term load, maybe 5-10 minutes. I think SW 2 is the only one you can run at Ford's rated current full time. I wouldn't go over 20 amps for SW1 under any condition.

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