Hmm... With the switch in play the wires get hot, without it it's fine. Are you talking about the wires from the battery to the switch, from switch to the lights, or lights to ground. Just my advice from my lights and wiring. Scrap the 70's wire harness. For 4 150w bulbs I'd recommend running 10 gauge wire. Get a heavy duty toggle switch from walmart. I'd say a 30 amp or so. Also pick up a bus fuse holder, and a box of 25 amp fuses. Make sure you DO NOT zip tie the wires tight against the bar. Make sure you wrap them in wire loom or some kind of insulator, and zip tie them tight enough to stay put but have some play. Yes the wire is insulated, but the amount of current your drawing is enough to jump the insulation and short it all out. I have 4 55w Hellas on mine right now and zip tying those small ones were enough for it to jump and cause me hours of headaches and blown fuses and rewiring it all only to find out I cranked the zip ties too tight.
Run a wire off your positive and install the fuse holder (empty to start) then run the wire to the toggle switch. From the toggle switch run a ground wire to a clean, paint free location on the firewall or metal support under the dash (loosening a bolt and wrapping it around then tightening it down works best) then run a positive from the switch to the light furthest from the drivers side by going up the drivers side, and all the way across the bar. Then run your positive wire from your lights to the positive wire, and connect them using quick connect splices. For the ground do the same but start at the light furthest away, run it across the bar and into the cab where you need a clean good ground. Then splice your ground wires in using the same method as you did your positives. Now insert the fuse into the holder. Flip the toggle and enjoy your lights.

 

[/QUOTE]

Awsome heres to lead sleads and 4x4s!!!

My Jeep...

My Land Yacht

 

i was bypassing the switch to turn the lights on and off.
so what i need is somthing like this?
oh and all the grounds for the switch and lights too i forgot those in my masterpeice below

 

Awsome heres to lead sleads and 4x4s!!!

My Jeep...

My Land Yacht[/QUOTE]
haha nice i like

 

Here is a good diagram depending on how many you are running you may need to run them in a series off a single relay or in parallel from multiple relays according to the how many watts they will use.

 

oh wow thats a nice diagram u just saved me hours of headakes thanks so much. i think ill end up just doing that for two lights each so ill have two switches and two relays

 

Ya sure glad I could help.
Have fun be safe and god speed...err somthing like that.

 

lol yea thanks man

 

oh hey dude did you get that measurement for those lights? i need to know the height from the mounting surface to the top of the light and also the exact diameter of the light. anyone out there can help me with this? i'm starting on my rack today and need to know these measurements for the mounting tabs and stuff.

 

tactical.. go to kchilights.com they have the mesurments of everything.

 

ill go measure right now for you

 

ok i got the lights wired and done that was a pia i ended up having to redo the whole wiring harness on the lights. and sorry i didnt get ur measurements yet ill get em soon as i get home

 

don't worry about it...i found them online. i started my rack today...go check out my build thread...not good!!!

https://www.cherokeeforum.com/f46/st...k-90-xj-35908/

 

i think there bright enough

 

haha you cant even see your jeep!