Mast Wiring through haul / top deck

[ChiTownSail]

Curious to know what the best bet is on running (new) wires through the haul. Attached is a picture of the mast step area and the wires. I would like to run the VHF antenna wire up, the GPS antenna wire, and add an anchor light, and possibly some spreader lights. The existing wires are for anemometer & wind direction, and the steaming light. There appears to be a small leak where the plug on the right is (in the photo), and I don't like how this is setup just on the top of the deck. I am thinking of adding another block (of wood) if you will, next to the mast step. But I am concerned about sealing it off, and creating a seam between the step and the new block. I am sure several of you have run wires of some sort, and I am wondering how it was done. I'd like to do it once, do it right, so I won't have to touch it for a long time.

Thanks for the input.

 

[AXEL]

On my boat, a 1977 C30, obviously I used lugs and fittings to disconnect the wires from the mast. But to run the wires thru the deck I simply drilled a big enough hole. I used a 3M product (I forgot which one) but it is water proof and remains flexable. I haven't have any problems in close to 10 years so far. The wires come thru in the head. I used a 6 foot lenght of white PVC in which it cut a small channel through the entire lenght so I wouldn't have to run the wires through. I mounted the PVC to a corner in the head (nice neat job of course) then run the wires to the fuse pannel. Looks good, works excellent, didn't break the bank.

 

[Scott T-Bird]

It looks like you have 2 holes for wire connections, one thru the aluminum foot and one thru the coach roof. I would think about consolidating if you can run them thru the foot and close up the coach roof hole. I like that because it is slightly elevated and seems like it should shed water more easily. It should also be easier to seal from the top. You might not have enough space next to the mast though. I think some have extended conduit (and sealed around the conduit) above the roof to keep water out of the hole and then merely seal the top of the conduit as best as possible. Water can still get in thru the conduit but should not be damaging to the core of the roof.

I am totally lost on what you just said Axel. 6' length of PVC (pipe)? What does that do? Does it fit thru the hole you cut and extend above the roof to the sole of the head? A small channel was cut in the pipe to run wires thru? Don't you just thread the wires thru the pipe? I'm sorry for the confusion, but I can't be the only one ...

I am curious because I have my wires run thru a hole underneath the deck-stepped mast. It leaks from water that gets inside the mast and I need to solve this issue while my mast is still down this spring. I thought about routing out my hole to extend a conduit that would extend inside the mast for a few inches. Then I would seal the joint between the conduit and the hole. My other option is to cut a hole at the base of the mast and run the wires out the side and thru a new hole outside the mast. I would then close up the hole that is bored thru the mast foot. I don't like the sight of wires outside the mast at deck level, though, and the roof area is limited enough without putting a trip hazard next to the mast.

I know simplicity is a factor. I have to plug the connections together and stuff them inside the mast while the mast is lowered to the foot. I worry about losing my fingers if the mast slipped. I have used a stick fashioned to aid the task because I cant stand the thought of ending my life without fingers!

A plate on the side of the mast would be far more convenient, but I don't like the wires on the outside.

 

[AXEL]

The 6' pvc is simply for astetics to dress the wire bundle neatly against a corner in the head where it breaks thru the deck.
I drilled a hole and run the wires next to the mast step. As mentioned I use a 3m product to seal this hole and it has been water tight for 10 years. The wires are run very close to the mast step. It looks fine. I attached a plastic project box (Radio Shack) to the mast near the step. Inside is a terminal board (radio shack). Wires from the mast and deck are connected inside the box. This way I can do maintenance on the connections if necessary. I step my mast every season, the boat comes home every winter and stays in my driveway.
If you look in the photo you can see the black box (in red circle at base of mast) and the wires running out to the deck.

 

[Ross]

A standard wet location PVC junction box will serve perfectly well.

 

[Scott T-Bird]

Ok, now I see. It seems his question is the best method for sealing that hole and keeping water from penetrating the core of the coach roof. I know that mine is a problem as it stands and it needs to be addressed before the core is irreversibly damaged. I don't really like the idea of simply plugging the hole with a sealant, without diverting water away from the opening. It seems to me that water will seep along the wires no matter how flexible the sealant is.

 

[ChiTownSail]

These are all great ideas, I do like the idea of running a box at the mast to plug everything in...but I will need to seal off the hole like mentioned above. I would agree something needs to be addressed before the core is damaged irreversibly...

 

[Scott T-Bird]

As far as where the plug connections are, I have no desire for a junction box outside the mast if the plugs can be located inside the mast and all that exits the mast are cables. A cover plate can seal the mast opening. That would be a problem if the mast section is small, though, and the mast section of the Hunter 25 does not appear that roomy. So a junction box may be the better option there.

 

[ChiTownSail]

Ok that sounds good, so running the wires through the deck then just entails a lot of sealant and that is it? I want to make it clean, but that may be the only way to do it.

 

[Scott T-Bird]

I imagine that Axel possibly has the individual cables bundled tightly and wrapped so it is essentially one cylindrical bundle passing thru the deck? That would offer the best chance at sealing the penetration it seems.

 

[Ross]

There are wonderful flexible electrical conduits and fittings made for industry that are made to be disconnectable and completely water tight.

 

[AXEL]

I imagine that Axel possibly has the individual cables bundled tightly and wrapped so it is essentially one cylindrical bundle passing thru the deck? That would offer the best chance at sealing the penetration it seems.

Yes the bundles which consist of several 2 conductor wires (spreader lights, steamer and mast head lights) and the VHF antenna were pulled tight together ( VHF does have a connector but it's in-line and stored in the junction box). Prior to adding sealant the wires were separated and sealant was spread around between the wires to be sure the sealant got in-between and made a good seal. Then the bundle was pulled together (use a nylon tie wrap to hold them together) and more sealant added around the hole (use masking tape to avoid a mess, remove when things cure). I agree this may not be the prettiest method, but it was the only way I could think to bring several electrical wires thru the deck. In the past I have used "plug" type thru hull connectors and they always fail, corrode up. This method has remained water tight for 10 years+. Don’t skimp on the sealant. Use the best (usually the most expensive) 3M product, one the will remain flexible and water tight.
The idea of inserting (epoxying) a short piece of PVC in the thru deck hole is a good one. This would seal off the core. If the PVC extends above the deck about an inch or so it could prevent water (wash or rain) from penetrating. If I was to do it again I would use this idea.

 

[Scott T-Bird]

Axel, thanks for clarifying that. I think that if you created a cone with the sealant above deck to divert water, that would work well. Making sure that you don't create a dish is the key.

 

[ChiTownSail]

All great ideas. Hopefully once all this rain stops around here I can get some work done. I'll let you all know how it turns out.

 

[Scott T-Bird]

Northsider ...

Maybe the Cubs could win a ball game if the rain stops. My tolerance for futility seems to be inexhaustible, but I have to admit that I am disgusted. I was born on the north side (well, techically, Evanston), so I can't help what's in my blood! My kids were born at Swedish Covenant so they are cursed, too!

 

[Ross]

Epoxy won't bond to PVC!