Baja Spy Rack Install Hidden wires

davester00

New member
Baja Spy Rack Install 2.0 (hidden wires). Rack game on fleek!

Purchased this Baja Spy rack in Jan from the GB Ramon put on. Mounted it on just to be able to use it. Took it off to add illumination thus the 2.0.

I really like the end result as I am going for a clean , grey scale, low-key look. That is why I opted for the folding functionality of the Spy rack and put the single row bars between the rack and the roof of the vehicle.

After some feedback from Arknabbit my neighbor ex-ricer now pro-am drone racing pilot and bouncing off some ideas off wild_turkey.I grew the balls to remove the rack and drill it to hide all the wiring for a super clean install.

Finally got around to getting all my lights:
40 " Dual Row 4D 7W front
2x 12" Single Row 4D 7W sides
31" Single Row 4D 7W rear

It was a pain in the ass to get the wires to curve inside the 90 degree bends of the rack. After drilling holes I used a Hornady 5.56mm FMJBT 55 grain projectile taped to fishing line as a wire lead. I lifted the rack so that gravity will take the weighted lead to it's final exit hole. Once I saw the lead come thru I used it to pull a 16 AWG lead wire , then the actual wire.

The 40" light bar and actuator wires ran down the drilled A-pillar mounts then the drivers side rain gutter (4 total).

2 side lights pos. wires were consolidated. Ground wires for the sides and rear lights were also consolidated (3 total), then thru A-pillar mounts, rain gutters and the connectors for the lights and actuator were joined in both sides of the windshield valance.

The 40" bar was wired to a separate relay 80A relay. Sides, rear and grill were wired to a Cooper Bussman fusebox.

I used overpriced AOB switches wired to a fuse tap then separate 3A mini ATM fuse holders were used for each of the switches.

For the drilling I used a corded drill with Norseman drill bits (borrowed from work), dremel to debur the holes before the grommets were installed. Black silicone was then used to cover the grommets and wires to create a somewhat water resistant seal.

Anti-theft (AT) hardware was purchased from Marshalls industrial supply. For extra security black shoe goo was placed over the AT hardware that was installed on the light bars and their mounts.

After all I don't regret doing this install as it is super clean compared to what I think I would have done without drilling. Hopefully this is the end of these time consuming tasks.

Hope this work will stand the test of time, who know how long it will be before some little punk-azz tries to throw shade and take off with one of my lights.
 

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Switches

I used AOB Air On Baord, which I realized are "expensive".
Toyota Switches -Air On Board

In hindsight I would have purchase the OTRATTW 6 switch panel and put them in the bottom cubby of the center console. I find that a rocker gives you tactile feedback as to the status of the switchs "on or off". The AOB switches although OEM looking and in a handy location for quick activation, you must confirm visually and remember the color of "on". Also, I found out along with other members that I'm running out of space as I would now like to add wishlist switches for : winch, air compressor and locker.
https://www.otrattw.net/
 
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Looks super clean Dave! I like how the single rows sit between the rack and the roof. That will be nice when you get an awning.

What's the up down switch for? The spy light system?

If you're running out of switch space, there are 2 locations in the glove box. The switch blank where the USB was installed on older models like we talked about. You can also use the cigarette lighter plug blank, but not with an OEM style switch. It doesn't really matter much since its in the glovebox. Perfect for things that oh don't need to turn on when driving, like a winch or fridge power.
 
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switches

[MENTION=130932]wild_turkey[/MENTION]

Yes, the up and down arrow switch is for the actuator to move the LED bar up and down.

Also, I was wondering how you positioned your rear facing lights? I did mine so the light pattern is most useful when I'm looking in the rear view mirror from the drivers seat or turning around looking back out the rear window. Did you position your rear facing lights the same?

I just confirmed the location of those blanks in the glove box. I wouldn't mind mounting a winch switch in there if there was one with "level 1" protection meaning it cannot be turned on with just a soft press like the AOB ones.
I can imagine asking someone to get or place something in the glove box and accidently turning it "on" and me not realizing it's status till 3 months later. Would you know of a more secure switch solution or you think it will be ok in the glove box?

[MENTION=138275]jimster716[/MENTION]
We all know that REAL pistol bullets start with the number "4" as in .4T5 ACP and REAL rifle projectiles start at .30 caliber, non of this .223 5.56mm BS.
 
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Can you tell me what mounts you used for the side and rear ones? Any better pictures of the sides and rears mounted and on the car?

I need to do the same thing but am considering doing it with wireless relays so I can turn the lights on from anywhere in camp and when I am in my RTT.

Great work and thanks for posting.
Cheers,
Keith
 
Mounts/Pics

[MENTION=123786]Keith_PDX[/MENTION]
Sorry for the late reply.
I was trying to get more pics in the sun but they don't look any better than the 5 other ones I took before so this might be the best I can do.

For the ebay click mounts. search "1 Pair 1" LED Light Bar Round Bull Grill Guard Roll Cage Mounting Bracket Clamps"
I contacted vendor and purchased 3 sets so I was given a "discount" ~$75 for 3 sets shipped. The mounts are aluminum and I had to drill hole in the center bracket larger to pass my hardware thru. I used a drill press without a proper vice so it made the drilling sketchy to say the least.

As for the lights, my application is to use them while in the SUV driving. Therefore I went with 7w bulbs for intensity, single row so I could mount them between the rack and roof for the low-pro look, flood lenses for sides and rear except rear middle panel. I also angled them so the light beams are optimized while I'm in the drivers seat.

If you are going to use them for camping or while being outside I would probably do <7w bulbs and dual row since the beam projection of a 7w single row is intense and vertically narrow. Also, since I used lock washers and covered anti-theft bolts I can only adjust my lights a few degrees up and down. I don't know if adjustability will play a factor since you have a RTT, canopy and want to do remote relays which I think will be awesome.

Let me know if you have any questions about the other hardware I used to finish this project, I'd be happy to help you out.
 

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[MENTION=112589]davester00[/MENTION]

Thanks for posting these pics, I am in the middle of installing a Rigid 40" E2 on my Spy rack as I type this. (Going to be a late night). A few questions. I noticed the up/down switch is a little wider than the OEM plugs and AOB buttons, did you have to modify anything to make it fit? I see you moved the AC power button, I attempted to do this as well, but the slots were slightly different (admittedly I didn't check the one you ended up using), any mods required?

Thanks!
 

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