Pod Light Wire Gauge Calculator
Choose your lights, measure the wire run, and get the wire size (AWG), fuse, and relay to use for a bright, safe install.
Vehicle system voltage
Lights on this circuit
Add every light that will run on the same switch, relay, and fuse.
Wire run length
Measure along the route the wire will actually follow, not in a straight line. Typical: fog lights 4–8 ft, A-pillar/ditch 8–12 ft, roof or chase 12–20 ft.
Install details
How this is calculated
- Current: total watts ÷ system voltage. For lights that list amp draw, we use the published watts or amps from the Cavalier product page.
- Voltage drop: current × copper resistance per foot × circuit length. The circuit length is the out-and-back distance with a battery ground, or the run plus about 2 ft with a chassis ground. Resistance includes a 15% allowance for warm operating temperatures.
- Fuse: 125% of the continuous load, rounded up to the next standard blade-fuse size. The wire must be rated for at least the fuse size so the fuse blows before the wire overheats.
- Wire ampacity: based on single-conductor, 105 °C-rated automotive wire (GXL/TXL) outside engine spaces, with a 15% derate for engine-bay routing. 18 AWG is the smallest size recommended for exterior lighting.
- This tool is a planning guide. Always follow the instructions included with your lights and harness, and use a qualified installer if you're unsure.
© Cavalier Lighting LLC. This calculator is a reference tool only. Vehicle-specific Cavalier kits that include a plug-and-play harness are already sized for you.
Wiring pod lights: common questions
What size wire do I need for LED pod lights?
It depends on the total amps and how far the wire runs. For example, a pair of Apex 5 Dual pods (about 9.3 A total) on a 10 ft run with a chassis ground calls for 14 AWG wire and a 15 A fuse. Longer runs or more lights need heavier wire (a smaller AWG number), so use the calculator above with your exact setup.
Do I need a relay for my off-road lights?
Yes, for most pod and light bar installs. A relay lets your dash switch control a small trigger current while the heavy current runs directly from the battery through a fuse to the lights. The switch wire can be 18–20 AWG.
What size fuse should I use?
Size the fuse at about 125% of the lights' continuous current, rounded up to the next standard size, and make sure the wire is rated for at least that fuse. Mount the fuse within about 7 inches of the battery so the whole run is protected.
Why does wire length matter?
Every foot of wire adds resistance, which causes voltage drop. Too much drop makes LEDs dimmer and can make the wire run warm. Keeping drop at 3% or less gets full output from your lights.
Do Cavalier vehicle-specific kits need this calculator?
Cavalier vehicle-specific kits that include a plug-and-play harness are already sized for that application. Use the calculator for custom pod, light bar, and chase light installs.
Is this calculator a substitute for professional advice?
No. The calculator is a reference tool that gives general guidance. Always follow the instructions included with your lights and harness, and consult a qualified installer if you are unsure.
Questions about your install? Contact the Cavalier team.
For reference only. This calculator provides general guidance based on the information you enter. Actual wiring requirements depend on your vehicle, wire and connector type, routing, and operating conditions. Always follow the instructions included with your lights and harness, and consult a qualified installer if you are unsure. Cavalier Lighting LLC is not responsible for damage or injury resulting from installation.