Troubleshooting lightbar wiring...

He did connect the light directly to the battery and still was dim, so can he assume the product is defective?

It's a consideration. If it were me, I'd connect it while the car was running to get a good ~14.7 volts, since he said the unit took 12-24V. I'm not sure to what extent he connected it directly to the battery, as that could be interpreted differently by different people; it could have simply been bypassing the switch or a circuit still through a poor ground connection.
 
This is driving me bananas...so I ordered a new unit(light) thinking the original product was defective. I benched tested the new one simply with a 9v battery and it appeared to work fine and was bright. So I installed the new one and again its dim, both with car off and/or running. To clarify, the old unit when connected directly to battery, I simply ran hot and ground wires from battery to light nothing else. The only thing I can think of is the fact the wires on the light are either nickel or aluminum, where as the wiring I ran to battery, switch, relay and light is copper. From my understanding this shouldn't make much of a difference. I'm thinking my last option is to run all wires again with nickel. Any ideas?
 
When connecting to the car battery, are you using additional wiring between the light and the battery or are you using the light bar's wiring directly to the battery?

Do you have any splices/connections etc in the wiring?
 
When I connected directly to the battery I just used like a jumper wire/test lead with alligator clips on both ends. No splices or connectors.
 
I've been reading this thread. OP, sorry you're having so much trouble. Something is puzzling me. You said you bought a new light and it worked fine when bench tested off a 9V battery. Then you tried it on your vehicle and it was dim. Two lights acting the same? Doesn't make sense. Have you looked at your battery connections? If you are getting a decent output from a 9V battery but not your car's battery, perhaps you need to investigate that closer.
 

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