Well, another weekend down and I can take another item off the to-do list... I finally wired up the lightbar. If you are like me, you may not feel comfortable about drilling a hole through your roof so I wanted to try and keep things as clean as possible and still feel good about water protection. I really didnt know where I was going to start so I dropped the headliner and once I got in there and could see the inside, a strategy began to form.
There is already a hole in the sunroof housing so I decided to use it. I originally wanted to try and comletely hide the wiring but it seemed to be much more convenient to utilize the existing hole. The problem was that it lined up just in front of the roof rack mount so now I needed to make sure it was not going to leak.
I drilled a hole from the bottom, up through the top using the existing hole as a guide. Of course, I started with smaller bits and worked my way up to the size I eventually wanted. You are going to have to plan your insulation strategy before you start drilling and in my case, I decided to use a heater hose that best matched the inside/outside diameters I needed.
Now, you need to pop off the top front cover for the roof rack and trim the two supports so you can drill a hole as marked below.
Once I had the holes all lined up and sized properly, I fed the heater hose up through the roof. Once you have everything in place, I pulled it up about an inch so I could seal it with RTV and spun the hose as I pulled it back down into the hole (in the hopes it would pull the RTV down into the hole and seal it well).
Now, I fed the lightbar cord down through the hose. You will have to carefully remove the connectors from the junction so they will pass down through the hose.
Ok, so now on to the wiring. There is plenty of room up above the headliner but choose your locations carefully. You dont want to be in the process of trying to mount up the headliner and find you are hitting something. I was carefull and everything went up fine the first time so take your time and think things through before you start wiring things up. I secured all my wires with zip ties and made sure there were no opportunities for shorts by having any sharp edges that could cut the wires.
I decided to run my power down the drivers side of the windshield column. Again, there is plenty of room as long as you are neat and pay attention to the location for all the clips.
I have an extra pair of wires in here for my strobes so I wont have to drop the headliner again when I wire them up. I installed a second switch for them since I was already in there.
Switch location is all about preference and for some reason I wanted to have it up in the console so I chose to install it just behind the sunroof switch. It was not the cleanest installation and I played with a couple of different types of switches but ultimately ended up with a flat rocker-style that lights up when the lightbar is on. I used a roto-zip to carefully clear the spot for the switch but be carefull as one wrong move and you can damage your console.
...and here is the finished product. As with everything, things could be done better but it is nice and clean and I am happy with it. The lightbar is a wonderful product, I highly recommend it. I had my first opportunity to light it up on a dark road and oh my, was it bright. It exceeded all my expectations 10 fold. It is a VERY nice setup. With it mounted where it is, I can actually open the sunroof and aim the light anywhere I want including behind me so that was just an added bonus.