H25...Getting to the compression post wiring

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Dec 8, 2011
68
Hunter 25 Chicago
I removed the Mast today, and need to run some fresh wires up. What is the BEST way to get behind the compression post to access the wires? I started to remove the large piece of wood that separates the starboard wall / bulkhead between the lav and the starboard seating area. It is pretty difficult to remove and I haven't gotten it off yet. It appears the small shelf above the lav is glassed to the haul.

What is the best way to get this off??

Thanks!
 
Dec 8, 2011
68
Hunter 25 Chicago
Has anyone had a compression post removed? Someone clearly has had to of, what is the construction? Is there steel back there or is it solid wood?
Thanks.
 
Jun 5, 2010
1,123
Hunter 25 Burlington NJ
Spar wiring for H25

The stock H25 compression post is three pieces of teak lumber screwed together to make a U-channel. It is screwed to the bulkhead with wood screws. Most of the mast step is actually ahead of the bulkhead, over the toilet compartment; so the post is only there to stiffen the bulkhead, not to take true 'compression' load. It's only a small boat.

In theory it is possible to run wiring down behind the stock post. BUT-- this would mean the wires go down through the mast and through the mast step, inside/under the mast. This is a leak disaster waiting to happen. The more proper way to do this is to have the wiring exit the spar through as small a hole as possible about 6-8" above the deck and to lead the wiring through the deck by some other means. This relocates the potential leak source and makes the wires accessible even with the mast stepped-- such when you forget to hook them up till after it's done.

On my boat I fabricated a fitting out of PVC pipe parts for the side of the mast. It's kind of ungainly-looking (but I spray-painted it black to look like something cooler). This fitting is mounted to the side of the spar with two screws, covering a hole about 3/8" or 1/2" in diameter (definitely no bigger). The fitting consists of a right angle leading to a hose barb, pointing down at the deck. The wiring runs through this; a piece of 3/4" hose is attached to the hose barb. In the deck below it is a stainless-steel through-hull fitting, installed upside-down (barb up), through which the wiring gets stuffed and to which the other end of the hose is attached. Water stays out by using good hose clamps and by leading the wires in a drip loop right before they go out of the mast.

Inside the head compartment, over the door, I have a terminal block to which the boat's ends of all these wires are connected. I am making a nice wooden box over this to keep it from shower spray.

You can do the same thing using one of the common through-deck connectors for wiring. Just be sure to bed it down properly into the deck, and that doesn't mean with silicone! (See my other posts. :))

BTW-- I replaced my compression post with a beautiful beam made of varnished white spruce. It's sold, about 3-1/2" square; but as I said the wiring isn't led inside it.

Also BTW-- please don't take
down the structural bulkheads-- there is no need to. My boat is 1974 and this bulkhead, especially since I treated its edges with epoxy, is sound and original to the boat. Leave it alone. :naughty:
 
Jan 17, 2012
11
Hunter 25 Chicago
DianaofBurlington
I am co owner with ChiTownSail and thank you for all your info.

Do you know what/how the wood that has the mast bracket attached to it is attached to the cabin top? and is that bracket bolted to some kind of plate or to the compression post somehow or just to the cabin top?

The bracket that the mast bolts to has 4 bolts that attache said bracket to the wood and go all the way thru the cabin top to nuts down below in the head area. We can only see two of the bolts and the other two appear to be somewhere behind the compression post.

Besides re working the wiring we are contemplating replacing the wood on the cabin top and resealing the entire area to eliminate a small leak.

Any additional thoughts are appreciated.
 

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Jun 5, 2010
1,123
Hunter 25 Burlington NJ
H25 mast step R&R

The bolts are of two kinds. The front machine screws should be reinstallled in the same holes-- but beforehand, wet out the inside of the holes in epoxy and, when it's dry, ream them through (gently) with a drill bitt for a fresh opening. Then apply a little 5200 or 4200 under the washers as you tighten them. Consider using hex-head cap screws for these with the heads facing down to have the threads and nuts out of the way. It doesn't matter which way they face. Use nylon-insert locknuts on these. You might want to fabricate a backing plate of aluminum or fiberglass for under the deck; but in general nearly all the load on a mast step is downwards-- towards the deck-- and side-to-side. It won't 'fall off' unless the boat goes upside-down.

The back bolts are SS lag screws going straight down into the top of the compression post. In reinstalling these, use a syringe to drip some epoxy down into the blind holes in the top of the wooden compression post. End grain is notorious for soaking up moisture-- however, it will likewise soak up epoxy really well. While the epoxy is still wet in the holes, run the lag screws in (slowly). When cured, the epoxy will keep the lag threads 'fresh' in the wood while also adding adhesion. If ever you need to remove this again and find them hard to budge, don't force them but apply direct heat from a soldering gun and it will warm the epoxy enough to let you back out the screws.

This of course relies upon your having a sound compression post in the first place. If it's questionable, don't live in denial-- its failure can cause the whole deck to cave in and possibly the mast to come down. A pro (like me) can get you a new one made. (Avoid pressure-treated for anything on a boat-- I have cited my half-dozen reasons elsewhere in these boards.)

Your photo doesn't seem to blow up; but from what I can tell that looks like a PO's mod and may be rather bodged-up. I would strongly consider replacing that mess with a tailored plate of G-10 or laid-up fiberglass. (You can find this at McMaster-Carr: mcmaster.com.) Planning to replace this allows you to chisel the heck out of what you have and to clear off the deck and start afresh. The new plate can be about 1/2" thick (this is a stock thickness) and cut to size. I would make it about 1-1/2" or 2" bigger all the way around, the better to spread the load. I would not mount halyard turning blocks through it but would use a stainless-steel plate for this-- Garhauer and DAMCo both make excellent ones that fit the H25' step. (I used the Garhauer one on my boat.) The fewer holes through the deck, the better-- and the plate mounted under the mast step transmits all the upward and outward pull of the halyard blocks in opposition to the downward compression of the spar-- rather a tidy cancellation of unnecessary arms and moments.

Mind that when cutting G-10, it will likely kill every tool you have. This is fiberglass to the tenth power-- so get carbide-tipped jigsaw blades and drill bitts, use plenty of water to keep them cool, clamp the part well, wear a mask and goggles, and go slowly and carefully.

Given a sound deck structure (having no rotting core or other problems), the SS mast-step plate should be bedded down with 5200. Be liberal with it; and be sure to sand the deck surface with at least 100- or 80-grit and clean well with acetone before application of the 5200. The one thing 5200 does not stick well to is dust.
 
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