Roof Rack Lites
I can possibly help a bit here
I have 6 lites on my "Surco" aluminum safari Rack: 2 fwd facing 150W driving lites, 2 100W halogen "alley" (side) lites, a rear facing white halogen to assist with backing, and a rear facing halogen amber Dust/ Emergency light (It can be switched either to flashing or steady amber). First of all, I reccomend using relays just as you would for front mounted fog/driving lights. The wiring harness comes up the "B" post (the one between the front and rear doors) on the passenger side,behind the interior plastic trim, then has "bullet" crimp-on connectors inside the car then out thru the door opening, behind the top weather strip, and up to the rack. I have 6 #12 wires, side by side. at first I had a slight water leak, but then I filled the area around the wires where they pass behind the upper weather strip, with silicon and ...end of problem. Also one of the 6 wires is an "insurance" ground that goes to a screw into the body metal, just inside the trim on the B post, near the top. I have had this set up on my truck for about 5 years with no problems. The bullet connectors make it easy to remove the rack, to convert to ski racks for winter, bike racks for summer etc.
As for the switches, I built a custom console for these switches and my communications gear. See the photo Rick took under Truckhaven 2000, " Ray Hutchjinson's Communications Center" you probably wouldn't need to be that elaborate, but with 7 aux light circuits, etc. I needed to do something!
Hope this helps
