Wiring up my roof rack lights-Deutsch connector

[Pikeman]

Ok so decided not to do the normal run the wires through the weather stripping as most have done. I bought a 8 pin round Deutsch connector to go through the roof. My original plan was to have it up front next to the sun roof. Well after taking the headliner out I soon realized that wasnt going to happen. I am also going to take the time to put some sound deadening material in with the interior panels out. I only took a few pictures yesterday while making the harness and getting wires run. The pins that go into the connector require a special crimping tool that didnt show up in time so we couldnt actually finish the install. I also installed a 6 fuse buss panel and made a mount for the relays. I will try to take and add more pictures soon but here are a couple for starters. I think the crimpers will show up Monday or Tuesday and will finish the install then. While we were running power we wired for the following lights. Roof rack Outer two with Eurobeam pattern, middle pair pencil/ spot beam, rear facing lights and also relay and switch for my bumper fog/driving lights. I also rerouted power for my HAM radio to the new fuse block.

 

[Pikeman]

Fuse block

Hole for the connector

Hole for the connector another angle

 

[Pikeman]

I used a piece of Roof flashing tin and bent it then drilled it out so that I could use 2 of the bolts that mount the brake booster. This keeps it nice and close to the firewall and limits the number of wires running through the firewall.

With Relays mounted

Some pictures of the wires run in a spiral wrap loom

 

[Pikeman]

Ok so it took a while for the special crimper to get here but finally finished my lights last nigt. I can't complain to loudly since it is a $250 tool I got as a free loaner tool. Anyways here are a few more pics.

 

[Singtoe]

Reserved for comment.

 

[Pikeman]

Reserved for comment.

I was trying to keep a few spots so the pictures would be next to each other. I welcome all comments. I can say the connector was a little bigger than I was expecting but had to go that size since each pin was rated at 25 amps. THe next size smaller the pins are only rated at 13 amps which meant individual power for each light and not a pair. I hope to end up with either HID or LED when money permits but for now the Halogen lights I am running pull 8.4 amps each or 17 amps per pair.

 

[Singtoe]

I was trying to keep a few spots so the pictures would be next to each other. I welcome all comments. I can say the connector was a little bigger than I was expecting but had to go that size since each pin was rated at 25 amps. THe next size smaller the pins are only rated at 13 amps which meant individual power for each light and not a pair. I hope to end up with either HID or LED when money permits but for now the Halogen lights I am running pull 8.4 amps each or 17 amps per pair.

I like the idea of a water proof bulkhead connector for the roof. It will look like it came from the factory that way.


A comment for you would be the idea of using circuit breakers on your relay board. They can be hard wired in, bolted down and forgotten about. If you do develop a short, the circuit breaker will pop and then reset itself. Find the short, fix it and the lights will be up and running again.

Just a friendly comment. Great work on the wiring though.

 

[Pikeman]

I can only take partial credit for the wiring. I hate elctrical, I was always my brothers tool b*tch since he was the electrician. I know how to pull and route wires but no clue on the connections. The wiring was laid out by a friend that wires up sand rails and is just as picky as my brother and I are about quality. I can take credit for the relay bracket and location and how the wires were routed. I dont have pics of it(yet) but the wire harness he made up top looks great. He ran the wires and then heat shrunk the entire run to protect it and make sure it stayed nice and neat.

 

[Pikeman]

Well found out they didnt even ship the loaner crimp tool until Friday. Further update once it gets here on Wednesday. I am hoping to have them completed and interior back in before my trip this weekend.

 

[Pikeman]

The lights on the roof are on two switches. First one is a 3 position Toggle Off, 1(outside pair Euro beam), 2 outside pair and inside pair(spots). The next switch is a factory fog light switch and controls the $19 driving lights facing the rear.

I will post a few more later.