I did this in the middle of last July in 110 degree heat and man did it suck. Took me about 6 hours due to having to get out of the heat, then forgetting to buy extra wires, then check on my 7 month old son to feed and put down for nap time....I have a Wilderness rack with 4 Hella 4000s in the front and 2 Hella 550s in the rear. I used that snake wiring cover to cover all of the exposed wires on my rack, then zip tied them to the rack. From there, I tucked the wires under the A arm plastic finisher using a flat head screw driver with electrical tape on the screw driver head. I know that sounds kinda ghetto, but it worked good and fast. After that, I mounted the Hella relays (3) to the firewall on the passengers side above the wheel well where there is plenty of space. By the way I had 3 wiring harnesses for the Hella's, the wiring for the 550s in the back didn't reach so I just bought some wire from Home Depot. Since I was there, I also bought some 10 gauge wire for a dedicated ground wire that is connected to the ground block that the negative wire from the battery is connected to run all 6 grounds since my rack has rubber footing on it and when offroading, if you ground to the rack (which I did at first) you will notice flickering from the lights. From the relays, I connected the positive wires to the battery, then the remote power wires I tapped into the postive wires since I wanted them to turn on regardless of engine on, and which lights are on. From there on I ran the switch wires through the open space where your hinges on the hood are. Its also where the vents on the back side of the engine compartment are. Used some more of that snake coating, ran the wires between the weather striping on the back of the engine compartment to the rubber grommet where all of the factory wires come out on the passenger side. I fished them through (they will fit with patience) to under the steering wheel where the fuse box is. Then it is up to you where you want to mount the switches. For me, since I had the Hella harnessing kit, I used the Hella switches temporarily because i wanted my hard work and lights up and running ASAP. So I went through another ghetto temporary result. I drilled holes in my coin holder to mount the Hella switches and ran the wires through the small square hole in the back of the cup holder assembly. After I realized that looked like total shit, I ordered the Discovery Series I Three-Switch Carrier (genuine), and 3 Discovery 1 fog switches. Since I bought the switches, I decided to buy the connector kit (will have to search on Expedition Exchange since its not on the lighting page). Very easy to crimp the wires into the connector then plug into the swiches. However, they only had one type of connector, it fit perfectly into the rear fog switch, but not the front fog switch. I had to shave off a plastic channeling tab that was slightly off by a few mm's. I used my wife's manicure set (cuticle tool). It has a "V" shape and the plastic tab shaved right off. Had to do it over a few times till it fit, but it did. Then I connected the #1 pin to the Hella positive power wire. #2 pin I spliced from the #2 pin wires from the factory HDC, gas door, etc. #4 pin connected Hella wiring back to harness. #5 pin was grounded to fuse box bolt and nut on the top of it. Never had any problems with the way I wired my roof lights. Now I know, I know...Why use a relay for this wiring method?? I just used the relay because I already bought it, it had the inline fuse on it already, and I just didn't want to cut and solder anymore wires since the Hella wiring has a connector that fits the relay perfect. This is just the way I wired my lights, and I'm happy with it.
atriot:
