Wire gauge and type questions

[SoloBronco]

I am still figuring out automotive electrical as I go down the road of adding lights and accessories to my Bronco. I appreciate the help with what seem like novice questions.



I am getting ready to replace the OEM factory fog lights on my 2023 Black Diamond with Capable bumper. I’ll be replacing them with Diode Dynamics Elite Series that are plug and play with the supplied wire harness. They come with a back lite amber option but their wire harness and install instruction suggest you use a wire tap to grab power for the back lite option.



I hate wire taps and would instead like to connect the back lite option into one of my empty AUX switches. The diode dynamics wire harness has an 18 AWG wire that they want you use to wire tap into someplace to grab power for the back lite function.



My plan is to connect the (2) 18 AWG back lite wires and extent them so I can reach one of my AUX switch wires(4, 5, or 6).



Here are my questions:

1. Should I use 18 AWG wires or 16 AWG wire to extent the combined (2) 18 AWG wires?
2. Tinned vs stranded (primary) wire? Pretty sure I don’t want to use tinned wire in a car that bounces and vibrates but would appreciate confirmation.
3. Are there any wire brands that I should look at vs made in china amazon product?
4. Is CCA (copper clad aluminum) wire OK? Or should I use something else?

Thanks in advance for helping educate me as I do this project.

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[GnormalGnome]

1. a single 18awg wire is more than sufficient to deliver power to the 2 backlights. If 16awg is all that was on hand, it would be fine, too, but overkill for the task.

2. Stranded copper wire for all automotive wiring unless manufacturer instructions say differently.

3. Support businesses in your community - visit a small hardware store or locally owned Napa store. There's an expert there more than willing to assist you get exactly what you need.

But yes, if you fear contact with humans, the amazon driver will leave you a box with overpriced wire of unknown origins.

I prefer a place like Wiring Depot but they're more like the Costco of wiring...best when purchasing in bulk.

4. See #2 above, stranded copper wiring only.

 

[CalvinT]

1. Should I use 18 AWG wires or 16 AWG wire to extent the combined (2) 18 AWG wires?
2. Tinned vs stranded (primary) wire? Pretty sure I don’t want to use tinned wire in a car that bounces and vibrates but would appreciate confirmation.
3. Are there any wire brands that I should look at vs made in china amazon product?
4. Is CCA (copper clad aluminum) wire OK? Or should I use something else?

1. 18 AWG wire.
2. Always use stranded copper wire for automotive wiring. Solid wire will end up breaking.
3. Stay away from wire sold in automotive stores. The insulation is usually rated for 80C. The insulation in your Bronco is rated for 125C. Also it's thinner.
4. Never use CCA wire, not even for jumper cables.

Delcity.com is an excellent source for wire, connectors and tools.

Wirebarn sells wire by the foot.
https://www.wirebarn.com/

Wherever you buy, look for wire with cross-linked insulation. That's what all the major manufacturers use.

For more information:
https://www.iewc.com/resources/technical-guide/automotive-primary-wire

https://www.awcwire.com/allied-univ...lGdXD7Hu4LKKnYJQHfpKPdU05xVdE-KbgB9mYs28qauly

 

[Brian_B]

I tend to not use any wire smaller than 16GA unless I have to just because it's hard for my ham hands to work with. It absolutely won't hurt anything going up a size bigger than needed.

As far as connectors - stay very very far away from those T-Tap style adapters. They are all junk.

A crimped butt splice ~can~ be good, but you really need the appropriate crimper to go with the splice (some brands have specific crimpers), and you absolutely need to give it a good tug test. Make sure to use heat shrink or something to ensure dirt/water don't get in the lug.

For smaller connections, I like soldering unless it needs to be disconnectable - then you get your pick of various automotive connectors (Deutsch DT is a popular one). For larger connections (pretty much anything over #10), I like crimped ring lugs on a bolt terminal connection, but I have a hydraulic crimper for those.

 

[CalvinT]

You have to be careful soldering. Too much solder and it will wick up the wire and make it brittle.

Good quality crimp connectors are the way to go. The trick is finding good ones that don't require special tooling.

 

[Brian_B]

You have to be careful soldering. Too much solder and it will wick up the wire and make it brittle.

This is true. I happen to have went to school for soldering. It's not any harder than crimping, but just like there's a right and wrong way to crimp a butt splice, there's a right and wrong way to solder a wire. Just different tooling.

I would also say a bad job soldering is going to hold up better than a bad job crimping. Neither is good, mind you, but a bad crimp isn't any better than a T-Type connector. A bad job soldering (probably) isn't coming apart, but may snap just like a solid wire might.

 

[CalvinT]

A bad crimp could give you a hot connection because oxidation isn't sealed out. Bad soldering usually leaves you with a mess and wires that might break. I can't think of anything good about T-type connectors in an automotive environment.

 

[indio22]

1. 18 AWG wire.
2. Always use stranded copper wire for automotive wiring. Solid wire will end up breaking.
3. Stay away from wire sold in automotive stores. The insulation is usually rated for 80C. The insulation in your Bronco is rated for 125C. Also it's thinner.
4. Never use CCA wire, not even for jumper cables.

Delcity.com is an excellent source for wire, connectors and tools.

Wirebarn sells wire by the foot.
https://www.wirebarn.com/

Wherever you buy, look for wire with cross-linked insulation. That's what all the major manufacturers use.

For more information:
https://www.iewc.com/resources/technical-guide/automotive-primary-wire

https://www.awcwire.com/allied-univ...lGdXD7Hu4LKKnYJQHfpKPdU05xVdE-KbgB9mYs28qauly

I used CCA jumper cable wire as the power cable to my car sub amp, lol. Two years in service and no issues.

 

[CalvinT]

I used CCA jumper cable wire as the power cable to my car sub amp, lol. Two years in service and no issues.

With the right connectors it can be reliable. But CCA wire isn't as ductile as pure copper. Aluminum will work harden with flexing. Copper won't. CCA cables also expand more than copper if the connections get warm. That can lead to lose connections. CCA wires will always be one or two sizes larger for the same current carrying capacity. There's also a potential problem with electrolytic reactions with connectors if the copper coating is compromised.

If your power cables are supported and don't undergo temperature cycling they can be reliable. There's a reason no auto manufacturer uses CCA wire even though it's less expensive and lighter.

The connection to your sub amp isn't critical and doesn't carry a constant load. it varies with the music you're listening to.

 

[indio22]

With the right connectors it can be reliable. But CCA wire isn't as ductile as pure copper. Aluminum will work harden with flexing. Copper won't. CCA cables also expand more than copper if the connections get warm. That can lead to lose connections. CCA wires will always be on or two sizes larger for the same current carrying capacity. There's also a potential problem with electrolytic reactions with connectors if the copper coating is compromised.

If your power cables are supported and don't undergo temperature cycling they can be reliable. There's a reason no auto manufacturer uses CCA wire even though it's less expensive and lighter.

The connection to your sub amp isn't critical and doesn't carry a constant load. it varies with the music you're listening to.

Yeah, I won't argue it's the ideal setup. I was in a hurry trying to make use of a nice weather day, but didn't have the wire. For ten bucks I bought the 16 foot jumper cables local, then split them into two giving 32' of wire. I checked the charts and the gauge was fine for CCA penalty and the amp I used.

But I'm going copper for my upcoming Bronco install, as it will be carrying a load to two amps, and as you mentioned will likely see more movement off-road and such and with connections.

 

[CalvinT]

Yeah, I won't argue it's the ideal setup. I was in a hurry trying to make use of a nice weather day, but didn't have the wire. For ten bucks I bought the 16 foot jumper cables local, then split them into two giving 32' of wire. I checked the charts and the gauge was fine for CCA penalty and the amp I used.

I don't blame you. Don't want to waste a nice day. Plus it's good to finish a job while you're still in the mood.

 

[Wirenut20]

These use #14 gauge wire
https://www.4x4truckleds.com/crysta...hk_6Okqd7aV_9uciueFMJR4xYx3ED2gsruXHiPzUcYCNO

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