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Catalina/Capri 25/250 Sailor's Forums

Catalina 25 Specific Forum

Rewiring the mast.

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Hypobaric
Deckhand

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USA
2 Posts

Initially Posted - 09/23/2012 : 13:21:41

Hi, and thank you in advance for the help. I need to replace the deck plug for the mast lights. There does not seem to be enough slack in the wire for me attach the new plug. Thus it looks like I will need to run new wire. I have traced the old wire from the electrical panel to where it goes up the mast support from the bilge. I have reviewed all of the previous postings on this subject. I am still unsure how to get the new wire from the deck, across the top of the bulkhead, and down the mast post. If I drill out the deck plug hole enough to grab the old wire; can I attach the new wire and pull it thru from the bilge? Thanks.

Doug P. on Sirona
1989 Catalina 25 Tall Rig

Edited by - on

pastmember
Master Marine Consultant

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2402 Posts

Response Posted - 09/23/2012 : 14:13:50

Mine ran from the port toe rail area up and along the coach roof inside the main bulkhead in the head and then through the deck. If your wiring runs through the bilge then I think it was run by a PO. Therefore there is no telling how much wire slack the PO left. Running new marine grade wire on a path of your own choosing would be my call.

Edited by - on

Voyager
Master Marine Consultant

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USA
5352 Posts

Response Posted - 09/23/2012 : 16:20:30

Use plenty of silicone spray to help the replacement wire slip through the channel in the roof. Sometimes the cable jacket is a tad bit thinner than the original and sometimes it's a bit thicker. Good to check that first. Thinner cables will slip through a little easier, especially with the silicone spray. Thicker cable could present a bit of a problem.

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blanik
Navigator

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Canada
210 Posts

Response Posted - 09/23/2012 : 19:19:51

from what i read and my own experience, the mast lights wiring was put in a channel that's routed in the cabin top and was either glued (willingly or not) at the time of assembly or goes through sharp turns so it's impossible to pull it out... mine was certainly impossible to pull out so i drilled over the existing hole on the cabin top (ripping away the wires) with a 1/2" bit right through the roof (make sure it's angled towards the bow) it'll come out at the junction between the ceiling and the bulkhead in the bathroom, i then put a tape to close the hole and filled it with epoxy and redrilled a smaller hole (if there's a place water will eventually find it's way it's under those deck plug adapters no doubt...)
i then fixed the wire with clamps all along the bulkhead/ceiling line, right below the trim and drilled a hole in the bulkhead hidden under the cabin top molding "lip" where all the electrical wires go, i then used tie-wraps to attach the mast wire to the existing wires, i finally drilled another hole in the galley bulkhead to send the wire to the electrical panel...

as for the deck adapter, i didn't use the rubber gasket that came with it, i used sealer

Edited by - blanik on 09/24/2012 02:32:26

OLarryR
Master Marine Consultant

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USA
3440 Posts

Response Posted - 09/24/2012 : 03:48:49

When I changed my wiring, I did not realize at first that the existing wire couldbe removed. From past postings, I thought it was encapsulated between the liner and deck. So...inside the deck plug hole, I used a long shank drill bit and drilled at an angle forward and got the hole to come out just into the Head area...actually, the hole was in the rubber liner at the top of the bulkhead and so I did not at first see the hole since the rubber recovered the hole when the drill bit was pulled out. I then installed an Anchor brand 5 strand Mast Wire thru the hole and attached it along the bulkhead running it behind the head area and then past the bulkhead under the cabin seats to a new switch panel I installed in the front panel under the sink near the cockpit steps.

Later, when cleaning up wires no longer needed, I realized the original mast wire that runs along the bilge cover area and up the mast column to the deck plug hole was not encapsulated - A yank on it freed it. So...to answer your question regarding my '89, I believe if you widen that hole and attach a new wire to the original, you probably could pull it thru the mast column. If not...then go the route I indicated in my paragraph above.

BY the way, the mast wire (5 strands) I used as follows:
3 for positive leads to the mast - anchor, deck and steaming lights. 1 positive lead that I ran to a fan located on top of mast column in main cabin and then the 5 strand was my negative wire.

Some photos of fan and switch panel on my website - See new switch panel wiring button on the left of opening screen.

Edited by - on

Hypobaric
Deckhand

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USA
2 Posts

Response Posted - 09/24/2012 : 17:32:34

Thank you all very much for the advice. It seems that around 1988 Catalina changed the wire run from through the deck on the port side to through the bilge and up the mast support post. I'll try Larry's suggestion and let you know how it comes out. Happy sailing.

Edited by - on

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Notice: The advice given on this site is based upon individual or quoted experience, yours may differ.
The Officers, Staff and members of this site only provide information based upon the concept that anyone utilizing this information does so at their own risk and holds harmless all contributors to this site.