Picking the Correct Size/Type Wire

Alec R

Member
Sep 9, 2014
50
eLightbars
What type of wire should be used to install equipment? What size (AWG) should be used? How to determine AMP draw? 

Discuss!

Please keep it clean and organized, this forum section is heavily moderated to keep information organized. We're going to use content from these discussions to compile a helpful guide for users seeking information about products in this industry.
 

Jarred J.

Lifetime VIP Donor
May 21, 2010
11,580
Shelbyville, TN
Twisted wire for mobile installations. rate the wire for 125% of the load it will be pulling.

solid wire for house or "non mobile" installations

include larger gauge wire for longer runs.

discussion over... :D
 

7d9_z28

New Member
Mar 15, 2012
3,048
West Michigan

Steve0625

Member
Jun 23, 2010
1,213
Northville NY
Twisted wire for mobile installations.
I think you mean "stranded" wire. Twisted would be two or more insulated conductors like this:

awww.technologyuk.net_telecommunications_networks_images_utp.gif

(This particular cable has two twisted pairs.) Twisted could be made up of either stranded or solid wire, but stranded is much more common.

Stranded wire is made up of multiple conductors in a single bundle like this:

aimg.directindustry.com_images_di_photo_g_isolated_electrical_wire_flexible_pvc_7083_4360269.jpg
 

paff2

Member
Nov 30, 2010
842
Lancaster, PA
What's the best thing to tell someone why you don't use stereo wire for light installs. He wants to use 8 gauge wire called Audiopipe. It's stranded wire with more of a gel coating.
 

Steve0625

Member
Jun 23, 2010
1,213
Northville NY
What's the best thing to tell someone why you don't use stereo wire for light installs. He wants to use 8 gauge wire called Audiopipe. It's stranded wire with more of a gel coating.
You're going to install it in a motor vehicle. It needs to be heat and oil resistant. It also needs jacketing that is tougher than a gel coating.
 

paff2

Member
Nov 30, 2010
842
Lancaster, PA
You're going to install it in a motor vehicle. It needs to be heat and oil resistant. It also needs jacketing that is tougher than a gel coating.
That's exactly what I told him and he said he will only use it interior. [emoji16]
 

MtnMan

Member
Dec 20, 2012
1,533
Eastern PA
What's the best thing to tell someone why you don't use stereo wire for light installs. He wants to use 8 gauge wire called Audiopipe. It's stranded wire with more of a gel coating.
I'm pretty certain it's CCA (copper-clad aluminum) wire, which has lower current capacity than copper and is prone to failure at crimped connections. The insulation is soft vinyl that's excessively thick. And why does you friend need 8 AWG for interior wiring???
 

Steve0625

Member
Jun 23, 2010
1,213
Northville NY
That's exactly what I told him and he said he will only use it interior. [emoji16]
Then I'd tell him that he supplies the wire at his cost, your price remains the same, and he accepts the job with NO WARRANTY and releases you from all liability in writing. Just because it's interior doesn't mean that it might not be exposed to heat or chemicals. And if it's interior only, how is he getting juice from the battery to the interior?

I normally don't take jobs like this. If the customer thinks he knows so much about installs that he's going to tell me to use inappropriate wire, I just move on. It's not worth the hassle of a call back or worse.
 

Steve0625

Member
Jun 23, 2010
1,213
Northville NY

wilsonbr90

Member
Sep 30, 2013
1,427
Corning, New York
It's always a good habit to wire heavier than you need, that way should the situation ever arise you are prepared to adapt
 

QuincyC

Member
May 23, 2016
18
Rockport, MA
Okay so use 14 gauge wire and run a wire with inline fuse from the battery to the 4200 mini, Visor and Stick lights then run the outputs from the 4200 mini to the positive on the T3's/Dashlight and the Brown (Activate wire) on the Lightbars? Is it okay to use a lesser gauge on the outputs coming off the controller?

Is it okay if the 2 gauges of wire don't match up? I think the wires coming off the devices are of lesser gauge. (Looks like 18 gauge)
 

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