Keep Wiring Neat With These Tips

We four-wheelers customize our vehicles a lot! From tires and lift kits to bumpers, winches and auxiliary lighting. And that’s just the exterior of the vehicle.

Inside, we load up on assorted electrical and electronic gear (two-way radios, laptops, fridge/freezers, and such). Extra wiring is required to supply all that equipment. Done right, the arrangement will provide sufficient power for today’s needs – and accommodate future growth.

Wiring the vehicle is a valuable DIY project
Many people turn to a professional installer. That’s fine. But don’t be intimidated by the project. Adding accessory wiring is a valuable learning experience. Plus, it allows the owner to customize the wiring and plan for the future.

Important considerations when adding wiring include:

• Protection from vibration and sharp edges
• Watertight connections when necessary
• Well-marked connections to prevent confusion
• Attractive arrangement that doesn’t interfere with vehicle operations
• Capacity to handle additional electronics over time

What follows are some tips to improve your wiring. All of the discussion relates to 12-volt power.

Calculate power needs
Before beginning, make sure you understand how much current the equipment will draw. The wiring must match that current level, measured in amperes (A), of the equipment you’ll be installing.

Using underrated (thin) wire may cause equipment to run poorly. Worst case, the wires heat up and cause a fire. Always use the proper size (gauge) of wire for the equipment being installed.

Equipment runs on DC, so maintaining proper polarity (positive or negative) is crucial. Stranded 2-wire is generally offered in a red/black combination, where red is for positive and black is the negative. Never use wire that isn’t color-coded. It’s too easy to mix-up polarity as you run the wire.

Anderson Powerpole® connectors the preferred choice
All wiring requires some sort of connector. Choose Anderson Powerpole® connectors for your work. These are the handiest to use, and take the guesswork out of wiring. The connectors are color-coded for polarity, so it’s impossible to mix them up.

Want to daisy-chain a set of wires? No problem. The Powerpole connectors easily snap together. In addition, Anderson Powerpole connectors snap into a RIGrunner terminal block. More on the RIGrunner shortly.

For extra convenience, buy the permanently bonded side-by-side version.

SAE and MC4 connectors
You may have heard of SAE connectors and MC4 connectors. SAE connectors are difficult to work with because the terminals are not polarity specific. It’s too easy to mix up polarity while wiring a system.

MC4 connectors are best suited for wiring solar panels. They’re watertight, which is important for outdoor installations. But they also are difficult to work with. MC4 connectors require the installer to determine the polarity of each connection, and make sure that matches the rest of the line.

If you have MC4s, though, all is not lost. Purchase a prewired pigtail to convert an MC4 to an Anderson Powerpole.

Terminal blocks act as power strips
Multiple pieces of equipment require multiple sources of power. In the home you use a power strip. The equivalent in a vehicle is a terminal block.

Mountain Radio’s RIGrunner terminal block is ideally suited to our needs. Compact yet sturdy, this unit can handle up to 40 amps of power and five devices. Each terminal is fused separately; fuses can be changed depending on the equipment to be powered. (Caution: Don’t exceed 40 amps of total current draw.)

The RIGrunner is ideal for radios and smaller electronics. For heavier needs (fridge/freezer and anything with a motor) use a Blue Sea terminal block.

In either case, wire the terminal block directly to the battery. Although the terminal blocks may contain fuses, for added protection, install a fuse to the battery as well.

Get crimped the proper way
Crimping refers to attaching a small metal sleeve around the end of the wire. That sleeve end is then snapped into the accompanying connector. Crimping takes a little practice, but once you catch on, it’s fairly easy.

The TRIcrimp crimping tool is designed for Anderson Powerpole connectors. It crimps the metal sleeve onto the wire end and maintains the desired round shape.

MC4 connectors require their own crimping tool, the CT-MC4. Though similar in design to the TRIcrimp, it is distinctively different.

The key is to use the right tool. The wrong tool, say a pair of pliers, will smash the metal sleeve. The wire may attach to the connector, but the connection will be poor, and the device won’t work well.

Shrink wrap, then mark connections
Finally, shrink wrap and mark your connections. Heat shrink tubing helps protect against moisture (though it’s not secure enough to use outdoors). I prefer marine heat shrink tubing because it’s coated with glue on the inside. The glue melts as the tube shrinks, creating a tight seal. The tubing shrinks to 1/3 its original diameter. Pick a diameter that will cover the connector.

Using a metallic-colored Sharpie pen, mark each connector with its purpose or termination. This will permit quick identification of each connector.

Use step drill bit for precise depths
Do you cringe if you need to drill a hole in the vehicle? A standard drill bit will punch through and keep going. Only really quick reflexes stop the bit from going too deep. Even an inch or two beyond can mean damaging wiring or hoses behind.

The solution is a step drill bit. The ridged design allows the user to choose depths from roughly ¼ inch to a little over one inch. You can drill through the firewall or other surface confident that you can stop when you need to.

Protect wires with wire wrap, grommets
Sharp edges are found throughout a vehicle. Whether from newly drilled holes or a piece of equipment, that edge can wear down the vinyl coating over time. Split loom (also called wire wrap) protects wiring from sharp edges and hot surfaces. Split loom is available in a variety of sizes and lengths.

For added protection, use rubber grommets whenever wire is fed through a newly drilled hole. Grommets are available in a variety of sizes.

Where to get supplies
Having the parts and tools on hand can make quick work of any wiring project. All the products mentioned in this article are available through Powerwerx (https://powerwerx.com/). However, if you have a preferred retailer, take advantage of that. The key is to try your hand at wiring your vehicle for electronic gear. It’s a good learning experience and something you can be proud of. And it helps extend your four-wheeling experience.

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Did you miss the previous articles?

2024

2024-11-02 Secure Gadgets in Passenger Area
2024-10-07 Don’t Bleed Out
2024-09-14 What It Means To Tread Lightly While Four-Wheeling
2024-08-08 ANNOUNCEMENT: Prepare Now For Wildfire Evacuation
2024-07-06 Pack Naloxone – You May Save A Life
2024-06-10 Know When to Say When While Four-Wheeling
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2024-03-11 AI Can’t Replace Hands-On Training For Four-Wheeling
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Some Upcoming Events (click on the link for details)
The 2025 schedule of clinics and adventures trips has been posted on the web site.
If you are interested in Death Valley, the Rubicon trip and a trip to Utah in May 2025, prior to the first of the year send me an email to put you on the roster. You will be able to register on the web site after the 1st of the year.

See the entire 2025 Schedule

73 KI6FHA
I hope to see you on the trails!
Tom Severin, President Badlands Off Road Adventures, Inc.
4-Wheel Drive School
310-613-5473
www.4x4training.com
Make it Fun. Keep it Safe.

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Secure Gadgets in Passenger Area

Don't Bleed Out

What It Means To Tread Lightly While Four-Wheeling

ANNOUNCEMENT: Prepare Now For Wildfire Evacuation

Pack Naloxone – You May Save A Life

Know When to Say When While Four-Wheeling