This was a nightmare.....there is a reason I am a mechanical engineer and not electrical. I HATE this stuff. I am not posting how the wire was actually connected because Hella provides excellent instructions that even a cave man could follow. I am just posting how I ran the wiring and mounted extra lights.

I first started by running the power wire (red wire along back of engine) from the battery through the firewall and down to the lower kick panel on the driver side. This is where I am going to put the relay.




I then went about replacing the twist lock fuse with a water tight blade style fuse holder



Then took a little break. Trying to reach the back of the engine is incredibly hard after lifting the Jeep.....at least the bumper makes a great bench



Next I started to work on the wiring for the roof rack. I Have four lights so I wired them two and two and used splice connectors on the ground wires. Like so.


Once I got the ground run I did a quick test of the lights and quickly found out that 16g wire WILL NOT support four lights.....it promptly melted. Thankfully I tested this before I finished wiring everything. The relay is a 40a which should be plenty.

This meant a quick trip to Autozone for some 10g wire and then to radio shack (because Autozone didn't have any) for the connectors needed. I replaced the wire from the battery with 10g all the way to the relay adding a new blade style 30a 10g fuse holder as well.

I then re-wired the fog lights two and two with each pair connected by a section of 10g wire as pictured below. I used weather pack barrel connectors for this.



I then used another splice connector to splice the power wire into the wire for the lights. This is the little "white box" looking thing on the red wire. I then siliconed the hell out of it to make it water tight.

Next was the fun part and the part of no return.....drilling a hole in the roof to run the wire down to the kick panel. I pulled the little plastic end cap off of the roof rack and drilled the hole behind it so the wire will be hidden when the cap is in position.


Next was the fishing of the wire down to the kick panel which wasn't thaaaaaat hard. I loosened the two screws that hold the driver side a-pillar molding and then removed the back grab handle and molding. I then removed the sunvisor and center dome light and pulled the headliner down until I could see the wire. I pulled it through the roof and forced it down the a-pillar behind the plastic molding. I then crawled under the dash and looked up and it was hanging there. With a little effort I finished pulling enough down to connect to the relay. Once all the connections were made to the relay I then pulled the accessory panel and drilled a hole for the switch.

I got the supply power for the switch from the fuse panel on the passenger side. The ground and supply for the relay come directly from the battery. All power wires are 10g all ground wires are 16g.

Wiring all tied up. I could make it look a little neater but nothing is visible.


Now, the best part.




Just headlights

Now with fogs

 

Nice lights my man they look good.

 

Thanks, they sure were a pain in the *** to install......I hate electrical stuff

 

 

Just got my diff skids! I'll post pics soon.

 

Do you have a plug to remove the roofrack and lights or what? I failed to see that in the light install section of the thread.

 

No, you would be correct in that you didn't see it. I realized after I was all done that I didn't install one. I hate electrical wiring and I did good to get them done without burning my Jeep to the ground. I have actually acquired a flat blade weather pac connector that I will splice into the main harness at some point to make for a quick disconnect.

 

smashed the diff cover on a rock...got really lucky.



sealed it up and hammered it flat


Ordered a set of these



However, they don't match the color scheme so.....


Much better



Went to Harlan for Fall Crawl this past weekend
Going up a rock, my locker hand grenaded.


Bad locker

 

Wow! Surprised the locker let go with your size tire. Figured an axle or R&P would'a snapped first.

 

I live about 30 to 45 mins from harlan

 

Nice diff covers, sucks about the locker..Lights look killer keep posting mods and pics...

 

Yea thats what I figured. I talked to them this morning and they have decided to send just the little cup since it was the only thing actually "damaged." I just hope now it goes back together okay and didn't affect the life of it by wearing on those teeth.....I am worried now.

It was my first time up there and it was a blast! I bought a year long pass and plan on going again around christmas.

 

Man, to this day I still REGRET selling that thing to ya..... lol
Im getting my new xj thurs and ive been kicking myself in the *** ever since.....

She looks amazing though..... cant even tell where that little rasberry was on er.... lol


But o well, guess I get to bite the bullet and buy a new one.... 8(

Hows it all holding up though??? Was it a pain to get everything straightened out???

Be good~Paul

 

Yessir.... she got me through ALOT of ****.... lol

Those bumpers are AMAZING.

 

It wasn't to bad to straighten up, nothing a torch and press couldnt straighten then I rewelded the cracked welds and welded the crash seams together ;-). The hardest thing was fixing the threads for the bolts that hold the bumper to the bracket. They were all jacked up. I still have on bolt that I can't get to tighten all the way. Other than that I bought all new hardware and added a few bolts holding the brackets to the "frame" and its done well. I have taken out a few small trees with it touched it up with paint and gone on. I have even made a few pulls with it and no problems. I still need to find a winch for it. I just bought some parts for my car so I need to wait a little while before making another large purchase.