ABSOLUTELY CORRECT!

I am an electrician and thats under code as a matter of fact. Thats for copper wire tho too. Which I do assume you are using. Your wire WILL burn up before it blows that 20amp fuse. Reason being that wire can only hold so much, #14 is around 16amps, but meant for no more than a 15 amp circuit. Manufactures make the wire just a touch more than 15amps for that little bit of le-way. You will notice the same thing with breakers, a 15amp breaker will actually blow at around 12.5. Its all to be safe. You have learned that the hard way.

NOW if you would have run #12 that fuse should have blown before the wire melted. Depending on the wiring it should have blown if fuse was before or after the switch. I don't know exactly how these are wired, if the switch is in series with the power to the lights, which i assume it is, then you just have to make sure that the fuse is between the battery and the lights. After the lights does not help.


To add to your post dirtydog,
I will not recommend using #14 for 130W bulbs, they will get hot. Just because it *works* does not mean much. If you have a voltage spike or surge, you have melted your wires, or burnt your truck to the ground.

Basically its better to be safe then sorry! In your case you would have needed a 15amp fuse in order to save that wire. Thats why wire size is always important. If you can, make it so the wire size is just a touch more then what you need. Then you will not have any problems with melting wires before the fuse blows....

 

WAIT , i just realized that they will probably be on a switched relay??? In that case your 20amp fuse should be between the relay and the lights. You said you used a 40Amp relay? Thats a little over excessive but if they gave it to you alright. So if I get this strait heres how you guys have it set up

Wire from battery to the relay, (thats the constant source for the relay)
Wire from relay to lights
Wire from relay to ground
Wire from lights to ground
Wire from relay to switch
Wire from 12V "switched" to Switch
Wire from Switch to ground

Do I have this correct, I know I would wire it like this...

IF so you would only need that 20amp fuse on the wire going from the relay to the lights. Probably would only need a 5 amp fuse on the wire going to the switch. Cause all that switch is doing is sending 12V to the relay to induce the coil in the relay to close. All depends on where you tie that "switched" source into (personally i would run a separate fuse block [tied directly into the fuse box NOT on any fuses]under the dash, even only for one, in case of further electronics needing a switch source)

 

Well guys I fixed it all tonight and got both lights working. I kept 55 watt bulbs in the ff just because I was in no mood to re wire them all up.

I went with 12 ga wire all around on the 100 watt lamps and it should be good.
I'm excited now only took two tries!

Next I gotta aim them better, finish putting loom over the wires and then try a find a new plastic pop out piece that I had the switch in. ( I messed it up drilling a hole in the center not thinking I would ever add another switch)

thanks for the good info guys and Shiloh I know you were joking with me. Haha

I'll get some pics soon. Maybe I'll drive out somewhere cool and shoot some good photos of the lights on, but I always feel lame for getting out and taking pics of my truck. Lol

 

Oh and I have two random 100 watt pilot off road lights that I thought about hooking them up behind my truck with a switch and then I can blind the he!! out of people I don't like. Or if a cop is trying to read my plates! Haha

I won't tho...