Did a little work the last few weekends so it's time for an update! Unfortunately I didn't take any pictures yet but I will get some up after my Joshua Tree trip this weekend.
I finished installing all the lights from KC and wiring up the switches. The 4 Pro-Sport lights were installed on the RRO lightbar on the roof rack. The installation of the actual lights was easy, as there were 4 tabs on the lightbar straight from the factory. It was as simple as putting a nut on the stud from the bottom of the light. The only issue I had was the nut I used was not the factory nut but a security (Penta) nut that I ordered through my work (they wouldn't sell to individuals and I happen to work for an electrical contractor so I just ordered them through the job I am working on). The nuts were very hard to tighten. The other issue was how to run the wiring from the light into the car and to the switch location. I ended up running the wiring down the sides of the roof rack, 2 on each side, (on the inside so they are not visible) using black zip ties to attach them. This was not my preferred installation but I does look good and is way less difficult than my original idea of drilling holes in the roof rack and pulling the wires through the rack. When the cables reach the back of the Jeep, they run on the roof for a few inches before diving into the tailgate and into the grommet for the tailgate wiring on the back of the Jeep. From there, I ran the wires along the top of the tailgate opening inside the headliner and down into the wall panel where the sub-woofer is located. I tapped the power off the 12V outlet (so I would only have to run the switch wires up front). The excess wiring was then coiled up and left inside the panel along with the relays. Then I taped the switch wiring to the CB coax I had run (I will touch on the coax later) and continued running the wire to the front of the car (below the door sills). I brought all these wires up behind the glove box and left them there until later...
Next was the KC Flex 20" LED light bar and 2 dual flex arrays. The 2 Dual Flex LEDs were very easy to install and I used the same type of nuts (Penta Security Nuts) on these as well. The 20" Lightbar was a different story. It just didn't quite fit where I had planned on putting it. The KC mounting bracket makes the thing a little wider and no matter what I did I couldn't get it to fit on the mounting holes and have it tuck under the RRO bumper bar. So we ended up drilling holes into the top of the RRO brush bar and installed it there. This meant that it was now the leading edge of my car which was not ideal but the only way I could fit it there. The next day before we wired it up, I was going over it with my Dad and telling him how uncomfortable I was with it's location and he had a great idea. Ditch the factory brackets and use some Simpson Strong Tie L brackets. We ended up running up to home depot and getting them. We then drilled the same 4-hole pattern as the small Allen bolts have on the back of the light bar (they are used to connect each "pod" of the lightbar together). We bolted the brackets on and got it to fit where I originally wanted it! Again we used the Penta security nut to secure it to the mounting tabs provided on the RRO Bumper Bar. The wiring for all three was run into the grill (in the bottom most center honeycomb opening) and then followed the wiring for the winch that we ran into the engine compartment and hooked up there. The switch wiring was run through the grommet on the passenger side, located behind the glove box. There is joined up with the switch wiring from the back of the Jeep.
During this work we were also working on the CB antenna and wiring. I attached the CB antenna to the roof rack using a PIAA aluminum light mount for motorcycles/ATVs. I ground off the coating on the parts that make contact (so it would have better grounding continuity). I then had the coax (RG-213) dive into the tailgate too (this time in the grommet for the washer fluid). From there it followed the lighting/switch wiring previously mentioned.
Next up was taking apart the interior in the front of the Jeep to remove the cubby and hopefully install the CB on top of the shelf created by the USB/SD Card/12V Outlet and cut out the back of the cubby to sink the CB back so the front of it would sit flush with the media center or at least sink it back enough for the door to close...Unfortunately, this was impossible.
There is a metal structure located directly behind the cubby which actually caused the CB to be pushed out even further (because the coax couldn't come in directly behind the connection point on the CB and therefore would have to make bends inside the cubby before connecting to the CB). That meant I had to install it somewhere else. The only other spot I could think of that would still be somewhat concealed and still accessible if needed was in the glove box. So I installed it there on the self (for the manual). I think I can install a better/bigger CB in the glove box (I had bought Uniden PRO520XL because of it's small size) with some small modifications, so I ordered the Uniden 980 Bearcat and will install it soon.
The last bit was to install the switches. I had done alot of thinking about the switches and where to install them. I had considered the LED ring style switches and the Rocker switches from OTRATTW but was having some trouble on where to put them. I ended up finding what I thought was the perfect place for the switches. When I had the cubby out I saw that there was room under the cubby towards the front of it. So I decided to just use the switches KC provided (I may switch them to the LED ring type later but I think they look good) and install them on the sloping section on the front of the cubby. This makes them easy to reach and the door can be closed if wanted. Also, I still have the shelf on top of the media center if I want to put anything in the cubby (plus there is still room behind the switches for stuff too).
Sorry for the long post and not having any pictures yet but I promise to put some up in the next week or two! I hope everyone is enjoying the build and if anyone has any questions, don't hesitate to ask!