Lightbar wiring advice

[Ape Factory]

I'm installing the JCR roof rack with light bar cutout.

I have a Rigid SR Pro 40" midnight light bar to go with it. https://www.rigidindustries.com/sr-srs-pro-40-mdnt-940214blk.html

The light bar draws 18.5 amps. I have a "generic" wiring harness with relay but I have no plans to drill up top in the window frame. I plan to use Ford's method of routing the wires found here: https://performanceparts.ford.com/download/instructionsheets/IS_M-15200K-BRL_BRRL_9-1-22.PDF

I mean there's no reason to use the extra harness at all, correct? I can just wire to Aux3 and should be golden.

That's at least my plan for now. I will likely add a bumper-mounted flood/driving combo at some point and have the upgraded Rigid Ford Performance driving lights in the inboard fog location.

-The OEM fogs are still wired to the light switch on the dash.
-The FP Rigid driving lights are wired to Aux 1 just as the originals were.
-The new roof-mounted light bar will be to Aux 3
-Not sure which switch I'll use for the bumper lights

I still have the OEM fog and new Rigid driving lights wired separately so I can run the fogs on the road day in and day out although I never really encounter any serious fog these days and I live in a major city. So eventually I may just wire both to the dash wire. Thoughts? Seems like all I need is the OEM fog connector/splitter to do that and not the Aux 1/Fog switch relocation harness.

Wiring wise, I currently have:
-Generic harness
-SPV 2-way Raptor OEM Fog Connector Splitter
-SPV Aux 1 & Fog Switch relocation
-A lot of extra 12Ga and 14Ga wire and a ton of D2 connectors left over from other projects when I was manufacturing trans cooler kits for dual clutch gearboxes.

I do plan on possibly adding a fridge to the rear for a road trip up North this fall. But there's a 12V back there so not sure if I'll need to run any lights to any of the other aux switches. I'll be adding a Starlink as well as a portable battery and solar panels. We may camp, we may glamp. Bringing a tent as a backup in case wildfires change our plans.

Can't really think of anything else I "need" at this point, maybe an air compressor although I won't be doing any serious rock crawling on this trip. I do plan on hitting up Engineering Pass in Colorado either on the way up or way back but not even sure I'd need to air down for that? There isn't much off roading where we're going, Glacier National and Yellowstone. Plus I don't want to get stranded or break down 1500 miles from home with the wife in the passenger's seat.

Thoughts and ideas appreciated!

 

[Ape Factory]

I ended up spending the entire day installing the rack and light. The rack installation was extremely fidgety to say the least but I got 'er done round midnight, LOL. I still have to connect the passenger kick panel wires and the wires under the hood but that'll take me all of five minutes. I'll let you know if it burns to the ground.

Curious, how do people aim roof mounted spot light bars? Aim where high beam end? And yes, it does fit out the garage. I still have about 3" clearance.

 

[Ape Factory]

Made the final two connections and viola, we have light.

 

[Bschurr]

Curious, how do people aim roof mounted spot light bars? Aim where high beam end?

I have a combination of flood & spot (KC Gravity Pro 6) roof mounted and aimed so they cast light about 2/3 of the length of my low beams. I recently did some night wheeling and this placement worked out great for me (not so much for the guy ahead of me tho).

Here’s a video taken from behind my rig and you can see the light pattern based on the on/off.

 

[Ape Factory]

Those are bright! Hoping to get out tonight and do an initial setup so that's helpful.

 

[Ape Factory]

Revisiting this. I went and removed the front section of the JCR roof rack, keeping the rear portion in place. I purchased the Rigid mounting kit for the light bar which still keeps it "low profile" and got all that installed last night.

I've looked around but haven't seen any wizardry involving cable management.

The amount of wiring needed for the rack is more than if mounting it sans rack. I still have the full-length lead coming off the Rigid light bar which is probably a good three feet. Right now I just have a few strategic zip ties holding everything in place. Not ideal obviously and I'll want something a bit more professional looking.

Is there anything out there to help with cable management that's nice and tidy? There's no real way to mount say a wiring harness clip/bracket onto the back of the light or the brackets on either side of the light. I suppose I could drill a hole in the Rigid brackets and install some sort of cable management that way but it's not an ideal location.

My gut tells me there's no real plug and play solution. I'm planning on making a "bridge" harness that'll bridge the length gap needed between setups. Not ideal either as it's just two more connections to go bad but it might be the best solution if no other options are available.

Light installed with the JCR half rack in place. Urban camo. Blending in to the building behind!

 

[Bschurr]

For wire management have you looked into wire loom or tech-flex? You can then use zip ties or Velcro wraps for managing the bundled wire neatly. For connections between wire segments use waterproof moles style connectors or for a more low profile solution, waterproof butt splices with heat shrink over the top. Good luck!

 

[Ape Factory]

I'm a techflex dealer but it's not so much the sheath that's the issue as having a loose wire(s) flapping around. I used waterproof deutch connectors, etc...but there's no way to really secure the wires in place, OEM quality so to speak, with some sort of a clamp. If it's just the light bar/brackets, there's literally nothing to secure the wiring to. With the rack, you at least have a cross bar.

 

[Bschurr]

I'm a techflex dealer but it's not so much the sheath that's the issue as having a loose wire(s) flapping around. I used waterproof deutch connectors, etc...but there's no way to really secure the wires in place, OEM quality so to speak, with some sort of a clamp. If it's just the light bar/brackets, there's literally nothing to secure the wiring to. With the rack, you at least have a cross bar.

Perhaps something LIKE THIS

 

[Ape Factory]

Can't get that link to work Bschurr.

 

[Bschurr]

Can't get that link to work Bschurr.

Sorry - I fixed it but here it is again as a direct link for your viewing pleasure. Since there are no good mounting holes for zip ties, I used a couple of these under my winch plate to manage the parking sensor wires - they work well!

Amazon.com

 

[Ape Factory]

Appreciated!