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Unread 11-18-2014, 07:10 AM   #1
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Default Wire size Q for accessories

OK I've opted for a extra 12v battery in the bag well to power my lights, 12v outlet, etc. I anticipate under 20 amps total draw so let's say I want a wire size to handle 25 amps to go the main 12v switch. This switch will turn power on to a 6 outlet fuse panel with ground bus to make adding stuff easy.

What size wire should I run to that switch and panel? I have some 16ga speaker wire. Is that enough? This will be running mostly LED lights and 12V outlet for phone chargers and the like. Right now I have two 6w lights for back up lights and plan to ad a 72W LED bar at some point. Maybe some dash/interior lighting who knows. If I add a winch later it will go straight to the battery.

Also here is the vid of the first phase of the build. More to come on that as I go.
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Unread 11-18-2014, 08:15 AM   #2
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Default Re: Wire size Q for accessories

I would use #10 gauge min, #8 to be on the safe size. I would also use a heavy duty battery disconnect switch.
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Unread 11-18-2014, 08:43 AM   #3
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Default Re: Wire size Q for accessories

I agree 10ga is good for 30amps if You keep the run under 10ft.

My Opinion:

I would add a 30amp inline fuse as close as possible to the aux battery positive terminal.

The positive wire would be split (near the destination) into 2 wires.

The first would feed a power outlet, this will be always on and it can be used to charge the battery with a battery charger or a solar trickle charge panel.

The second wire would go thru a 30amp 48v charger relay and then to the fuse box.

The relay coil would be powered by the key switch (18ga wire) so all your accessories get turned off when the key switch is off.

If you ever install a radio, the "Yellow" or constant power wire would get wired to the power outlet side and the "red" trigger wire would go to your switched power fuse box.
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Unread 11-18-2014, 09:26 AM   #4
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Default Re: Wire size Q for accessories

Be sure to put a fuse at the battery connection. For reference, House wiring uses 14G for15 amp circuits, 12G for 20 amp circuits. I would use 10G speaker wire for 30 Amp. It's a bit of overkill but you will have less voltage drop under load.
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Unread 11-18-2014, 11:33 AM   #5
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Default Re: Wire size Q for accessories

I don't think using home wiring is a good analogy here for wire sizing... since the voltage drop on the wire run is directly related to the current going through the wire, the percentage of drop as it relates to 12v is 10 times higher than the same current on a 120v circuit.

Here is a good reference for DC wire sizing:

I would also use automotive GPT primary wire.
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Unread 11-18-2014, 12:52 PM   #6
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Default Re: Wire size Q for accessories

Yup, 12/48 Dc voltage drop happens a lot faster than AC120v, not a good comparison.
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Unread 11-18-2014, 02:47 PM   #7
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Default Re: Wire size Q for accessories

Great video Scott, can't wait for more to come!
Your cart appears much newer than a 93, the serial number above the go pedal will give the year. Since it's an IQ, it's at least a 2002.
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