D'oh! I have to add a mast inspection plate!

[Justin_NSA]

I missed pulling a cable thru when I stepped the mast. I am not taking it down again!
I saw mention of a cover plate from Rig-Rite. I'm going to order one today. I figure on using a 1 1/4" hole saw and cutting 2 holes so that I get nice curved corners top and bottom to avoid stress cracks.
I tell myself this will be a good feature if I ever upgrade the mast top electronics someday.

Electrical Access Plate: RR 72-99:
Electrical Access Plate is designed to allow access to internal electrical plugs above the mast step, without having to unstep the mast. Saves much in frustration and money by allowing you to check mast wiring connections with the mast up. SS Plate is 4 1/2" x 2" and is designed to cover a 3" x 1 1/4" vertical slot in the side of the mast, just above the top of the mast step. Plate is slightly curved to fit a variety of mast sections and attaches with (4) 1/4-20 RH machine screws (included).

 

[jssailem]

It has been done. Be sure it is big enough to get you hand in there. Also when cutting the access do not add to your challenges, do not cut wires inside the mast with a jig saw...

 

[Justin_NSA]

Thanks John. Yeah, it's a "Hail Mary" cut. I won't go deep. 3" x 1 1/4" should be a large enough hole to fish my cable and direct it down thru the 1" deck feed.

 

[jssailem]

If I had to do it I believe I would use a cutting wheel rather than a jigsaw. It is aluminum and it is likely thin. Hunter Extrusions are not like my mast. A regular street light like telephone pole. Your mast is a bit more graceful.

 

[pateco]

How much does this weaken your mast? My anchor light is not working, and I have tested and have no voltage at the socket. I am thinking it is the connector, but that is inside the mast with no access panel.

 

[jssailem]

Chip... Confirm that there is power to the base of the mast (or as close to it as you can. It may be corrosion at the panel). Then confirm that there is no power at the light (corrosion. Is the norm for most lights. Need to check wires and all connections. I like "corrosion block" to coat the connections). If all these indicate the issue is in the deck connection, then I would consider creating an access hole. You know the old saying, measure many times cut once.

 

[Justin_NSA]

+1 I looked at several 30' size boats on my dock. Several have inspection cutouts. Exhaust other options before you decide.

 

[pateco]

Chip... Confirm that there is power to the base of the mast (or as close to it as you can. It may be corrosion at the panel). Then confirm that there is no power at the light (corrosion. Is the norm for most lights. Need to check wires and all connections. I like "corrosion block" to coat the connections). If all these indicate the issue is in the deck connection, then I would consider creating an access hole. You know the old saying, measure many times cut once.

I need to go up the mast myself. I sent my son the last time, and he is a newb as far as electrics go. I was thinking it was a deadbulb so I sent him up with an LED replacement, and a meter. He tested with the meter and said he got nothing, but who knows. It may just have been a polarity issue with the LED. I can check if I go back up, just not looking forward to it. LOL

 

[dlochner]

When you pick the spot for the access plate there are a few things to consider.

If you mast has a conduit, make sure you don't cut into it. The hole should be below the end of the conduit.

Make sure there is enough metal below the hole to support the mast.

Don't put the hole in line with other holes. It needs to be offset to avoid creating a weak spot.

 

[Ron20324]

The hole in my B323 is maybe ONE inch. I assume you will have someone up the mast? Tie some nuts or other weight to a string. Lower it outside the mast from the in hole down to the out. Mark your string. Now, heel the boat to the side the wire is going in, and let the weight slide down the mast to the hole.

 

[JRacer]

I would not cut a hole that size at the base of the stick. Period. A whole lot easier to drop the stick now than over the side later. Just sayin.

 

[Ned Ludd]

My mast is 5" x 8" x 36' and has a factory 2" hole about 3" above the mast step. Just enough to grab the wire connectors and fish them out 1 at a time. There are many people who convert to in mast halyards who cut rather large access holes into the bases of their masts, we do not hear about failures being reported.
If I was doing it I would use a flush cut oscillating saw

Very easy to control depth of cut so you don't cut what you don't want to.

Measure twice...

 

[Justin_NSA]

Got my Rig Rite plate installed this weekend. I hole sawed two 1 1/4" holes fairly close together and filed the material between them so it looks like a vertical oval slot. I was easy to fish the missing cable back down thru the deck. I meant to take pictures but I was focused on getting it done.
Managed to splice my continuous furling line and bend on my headsail on. Just need to get the main on and we'll be ready to sail! It was too windy to bend it on Sunday.

 

[jssailem]

Consider a dremmel with a cutting wheel connecting drilled holes. Let's you control the depth of your cutting. It's when you cut deep you may cut something you don't want to.