SMD LIGHTING · INSTALLER TOOLS

Automotive Wire Gauge Calculator

Find a recommended copper wire size for LED light bars, auxiliary lights, and 12V automotive accessories.

Enter your installation details

Distance from power source to accessory, 3–60 feet

Choose the voltage expected during operation

Use the total running current for all connected accessories

Recommended wire size

Minimum recommended copper wire—
Estimated voltage drop—
Voltage at accessory—

Important: This is an estimated copper-wire voltage-drop calculation, not a complete electrical design. Check insulation temperature, wire bundling, installation conditions, fuse size, and manufacturer requirements. Protect the wire with a correctly rated fuse near the power source. For chassis-ground returns, actual resistance may differ.

How the calculation works

The calculator uses a 4% maximum voltage-drop target to approximate the original SMD 13.8V chart. It calculates current from watts ÷ volts when watts are selected, then estimates voltage drop using copper conductor resistance and a complete supply-and-return circuit.

Formula: Voltage drop = 2 × one-way length (ft) × current (A) × copper resistance (ohms/ft). The recommended AWG is the smallest listed wire that meets the voltage-drop target and a conservative general-purpose current-capacity screening limit.

Available wire sizes: 18, 16, 14, 12, 10, 8, 6, 4, 2, 1, 1/0, 2/0 and 4/0 AWG. Results are estimates at approximately 20°C; resistance rises as the wire gets hot. For long runs, heavy loads, or critical circuits, have the installation checked by a qualified professional.

View the original SMD wire gauge chart (PDF)