This topic has been covered SO many times and I tried searching for my answers before posting but each thread I found seemed to involve a situation just so specific and not providing the information I need. So I apologize for beating the horse dead, but here goes....

I bought 4 used Hella 4000's for a STEAL off eBay and they came with a bunch of wiring and fuses. I think I have everything I need to hook them up to the extra fog light binnacle switch but I don't know. Can anyone tell me based off of the photos I've attached if there's anything I'm missing for installation? A few people so far have recommended 12 gage wiring?
Cheers.

 

Weird wiring... Hella makes a great kit for 4000s that isn't very expensive, may be worth it

 

I think part of that has to do with the fact that they werent on a Land Rover before. Also, I feel like I researched the Hella kits and I think Hella said they don't sell the kit anymore and you have to buy new lights to get new wiring. But I could be wrong....

 

 

8 gauge. I'm an electrician.

 

This is my favorite kind of work

 

Is 8 gauge not a bit of overkill? Im down for the largest wire possible, but it can make routing a pain.

 

Like I said, 10 would work, but if it gets hot enough it will cook the insulation. 10ga is rated for 30A at 25C, the engine compartment would be well hotter than that. The derating would end up at around 20A. Now, because these lights will likely not be on all the time, you might be ok with 10ga.

For comparison, my 240w light bar came with 10ga wire. That wire still gets hot if I have the bar on for long periods of time. 240w @ 12v is 20A. 10ga is rated for 30A. 400w @12v is 33.333A. It's right on the cusp. 8ga is rated for 45A, which is overkill, but would definitely give room for running the lights for long periods in hot temps

 

 

You may find this helpful...

https://www.tessco.com/yts/industry/...get_wired.html

First, you need to find out the amperage draw of each light and where you will be mounting relay(s). Usually, l try to keep relays as close as possible to location of lights.



Relay for brush guard lights is mounted inside battery box area, three feet of wiring to reach lights. Easy to source voltage for relay and switch from under hood fuse box.



Mounted my roof bar light switches and relays behind sun roof switch location. First switch is back lights, double switch is the center lights and two outerlights. Each circuit is controlled by a relay. Pulled power from dash fuse box, there is a terminal spade (unused) that became hot with key. Ran 12 gage wire (fused) to the relays from this location and then wired relays in parallel. Looked at using the foglight switch, but wanted to use a location for the switches that could not be turned on by mistake.



Drilled a hole in the roof, behind roof rail, kept wiring from relays at about four feet.



Also, just make sure you use appropriate size fuse for diameter of wire used. You want everything to work properly together, fuse and wire diameter have to match amperage draw.

Brian.