Deck core repair around mast base. Oday 23-2

[Project_Mayhem]

Nice work so far!

On my 25 the wiring was ran in the corner where the bulkhead met the cabin top but it was literally an unsealed hole in the cabin top. I ended up putting a deck connector (practical sailor has an article with testing of many connectors). where the hole was. I can recommend a few if you're interested

I found most of the wiring to be in good shape when I stripped it. If this is the case, I'd splice it with new cabling to go through the deck. I'd be happy to share some tips for a long lasting repair when you're ready. There are multiple ways to trace the wiring. Chances are that the mast wiring is dangling in the cabin, close to the hole. There will likely be three or four wires. Figure out which one is ground. Then connect a test light or similar device to measure voltage. Connect the ground and one wire at a time and have someone flip the switches on and off until you find the right one. Label the wire and repeat.

@Timm R Oday25 Would you be able to see what colors are on your wiring leading to your mast?

I'm sure someone will chime in with the correct answer but I'm curious if pure glass and mat would be too brittle for the mast step. My Catalina 30 had about a 1/2" of glass on top of the wood. On the other hand, cored decks weren't a thing until C&C did this to their race boats. Prior to that, decks were solid glass so I suspect that solid glass would be fine for you.

The composite stuff is great but very expensive. A well done balsa repair will outlast the boat

 

[Timm R Oday25]

Good afternoon . I apologize for being late to the party .
Most of the smaller Oday's ,under 27 feet had the wiring for the mast laid between the top hull liner and under the deck .
Almost impossible to remove or trace. The wires are effectively sandwiched in balsa, epoxy ,fiberglass resin . It was a clean and neat way to build . Project Mayhem and myself went to some type of quick disconnect cables . I went with Amphenol brand. Personal preference . I think I ended up choosing a nine pin connector .Steaming light ,anchor light, foredeck light ,you get the idea .
I really don't care much about the weight of the extra wires . I choose to have separate ground wires for each circuit .
The wires come through the deck just forward of the port bulkhead. From there they follow the top of the bulkhead , where they go under the liner and head back towards the rear of the boat . Makes sense ?
As long as you have the resin and catalyst out , do yourself a favor ,liberally coat the mast step in the bilge .
I found that years of moisture had saturated the step and allowed the wood to soften and rot away . "IF" the wood is in great shape ,then seal it . This way any standing water in the rather shallow bilge doesn't get wicked up into the mast support beam .
I found in our case it was , easier and in the long run for better to remove the whole assembly and start over . It took a morning at most . I soaked the mast support end that sat in the bilge with many coats of resin .