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Old 04-03-2015, 08:36 PM
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LED Light bar installation

Hey all! I am installing a 240W 40" LED light bar on the roof of my 04 Jeep WJ. I was wondering what gauge wire I should use? I was planning on using 12 gauge wire and routing the wires down the windshield to firewall, through the firewall into the engine bay. Do you think I will be okay using that gauge or should I use 10 gauge? My next question is was size fuse should I use? I was thinking either a 25A or 30A fuse since 240W divided by 12V equals 20A. I believe that is all I have for questions right now, thank you for the help!

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Old 04-03-2015, 09:19 PM
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Re: LED Light bar installation

Hi, I would personally go with the 10 gauge wire but the 12 gauge will be OK - both can handle 20A. There will be about 0.12 v extra voltage drop on the 12 gauge compared to the 10 gauge. Don't forget your lights will probably run at 13.2 v or so when the engine is running.

I would use a 25A auto reset circuit breaker. Circuit breakers are impacted by temperature, the colder it gets the less current they handle. A 25A circuit breaker will trip at about 19A (continuous ) at -4 degrees F and at about 21A (continuous) at 10 degrees F.

Don't forget to use good quality connectors as you will increase the resistance if the connector is small or loose.

Good luck with your installation.
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Old 04-03-2015, 10:53 PM
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Re: LED Light bar installation

Thank you for the reply! What gauge wire should I run from the switch to the relay? 14 gauge?
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Old 04-04-2015, 08:05 AM
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Re: LED Light bar installation

Hi, 16 gauge would be suitable but you can use 14 gauge if you'd prefer.
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