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Roof light bar wire routing

4039 Views 7 Replies 4 Participants Last post by  Leems
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Hey guys, I haven’t really seen much on here as far as how you got your roof mounted light bar’s wiring routes cleanly inside the cab, so I thought I’d show you my solution. I bought some light bar brackets from Hazard Sky, and installed a 42” curved light bar. After taking off the roof rails, the front has three of those shouldered riv-nuts. The very front one is just for the rail to lock into, and doesn’t get a bolt through it. So I carefully drilled out the center to 3/8”, and drilled a matching hole in the bottom of the rail. I then cut a small slot on the inside edge of the rail so that the wire could be run into the rail and down through the riv-nut. Then you can pull down the edge of the headliner for access and run the wiring the rest of the way down the A-pillar inside the trim. As a side note, be careful while drilling. If yo ugh too far, you could punch a hole in your headliner. Also, these brackets sit low enough that I’m not sure if a straight light bar would fit. Definitely buy a curved one for the best fit and aesthetics.

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Thanks for the write up and the pics. I will be doing this soon to my Cherokee. Do you have any pics of which rivnut you drilled through and how you routed the wiring down the pillars without interfering with the airbags?

AK4wheeler
There are 3 in the front and 2 in the back. The riv-nut I used was the very front one. It’s the only one that doesn’t have a bolt that runs through it.

As for the pillar wiring, I haven’t actually run the wiring yet. I ran out of time. I’m hoping to finish that up this weekend. But as far as airbag routing, just make sure it stays above the airbag, and don’t get the wires wrapped around it and you should be fine. I’ll get some additional pics this weekend if I can get it finished up.
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There are 3 in the front and 2 in the back. The riv-nut I used was the very front one. It’s the only one that doesn’t have a bolt that runs through it.

As for the pillar wiring, I haven’t actually run the wiring yet. I ran out of time. I’m hoping to finish that up this weekend. But as far as airbag routing, just make sure it stays above the airbag, and don’t get the wires wrapped around it and you should be fine. I’ll get some additional pics this weekend if I can get it finished up. View attachment 211911
What brand light bar did you go with, and where did you buy it? I plan to do a basket mount, but your wiring definitely looks like the way to go.
Glad my wiring can be an inspiration! The light bar is a Nilight 42” from Amazon. It was only about $70. Wiring harness sold separately. It’s cheap and Chinese, but had lots of positive reviews. Also, those few people that had issues got them immediately replaced by the company easily with no questions asked, so that’s nice.

Nilight 42" 240W Spot Flood Combo... https://www.amazon.com/dp/B01MY1W7AO?ref=ppx_pop_mob_ap_share
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Glad my wiring can be an inspiration! The light bar is a Nilight 42” from Amazon. It was only about $70. Wiring harness sold separately. It’s cheap and Chinese, but had lots of positive reviews. Also, those few people that had issues got them immediately replaced by the company easily with no questions asked, so that’s nice.

Nilight 42" 240W Spot Flood Combo... https://www.amazon.com/dp/B01MY1W7AO?ref=ppx_pop_mob_ap_share
Thanks, I'm probably going to have a couple more small floods on the side, and possibly a couple more on the rear. I'm going with a similar multi switch setup that that fits nicely in the little cubby on the left that I saw on a different post.
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With that much lighting, you might not get all the wiring through the hole in the riv-nut. You may have to use the nut on both sides and run wiring down the right A pillar as well.
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Digging up an old one here, but thinking that a lot of additional info is now available.

I've mounted a Pioneer Roof Platform on top of roof bars (on the stock rails, naturally) and now thinking about attaching two LED light pods to the platform and looking at the best way to get the wiring into the vehicle interior. Also where the power was connected. The firewall opening behind the brake pedal is pretty full right now.

Would appreciate any and all available info and experience out there.
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