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Pulling new wires thru mast

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jaydon
Navigator

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USA
156 Posts

Initially Posted - 03/31/2016 : 17:06:11

Well, we are starting to see some 60 degree days now, so it's time to get to work on the boat.
I have the new wire from CD and a new VHF coax.
Will everything pull thru ok, or should I plan on using some lube on the wires?
If you think lube would really help, what's the best (and no KY jokes)?
I thought of lithium grease or a rag with motor oil. Or, would vasaline be best?
Thanks.
Jay

Jay
South County RI
Cat 25 SR/FK/Trad
#5645
Wind Dancer

wanderer13
1st Mate

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USA
76 Posts

Response Posted - 03/31/2016 : 17:51:17

Jay,

Does your mast have an internal cable channel? Mine does not and when I replaced my mast wires, they pulled through without any trouble. I tied a messenger line when I pulled the old wires out. I wrapped the new wires in all-weather pipe insulation to keep them from banging around inside the mast.

1981 Catalina 25 FK/TR

jaydon
Navigator

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USA
156 Posts

Response Posted - 03/31/2016 : 19:50:25

I have the tube in the mast. Not too big a diameter.
Jay

Jay
South County RI
Cat 25 SR/FK/Trad
#5645
Wind Dancer

jduck00
Captain

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USA
313 Posts

Response Posted - 03/31/2016 : 19:53:34

If you need lube for pulling wire, go to pretty much any electrical distributor or even a Grainger and get some pull lube.

http://www.supplyhouse.com/Ideal-31-398-Yellow-77-Plus-Wire-Pulling-Lubricant-1-Quart-Squeeze-Bottle?gclid=CjwKEAjwlfO3BRDR4Pj_u-iO2U0SJAD88y1SW3IUKqlzZ5_sBreMz03IpDDgho84q54nCDT3EN9hvBoC-hvw_wcB

Jeremy Duck
The Lucky Duck
1980 SKSR Hull # 1850

RickR
1st Mate

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USA
25 Posts

Response Posted - 04/01/2016 : 01:42:10

Just completed this task. My mast does not have the conduit. Pulling the wire bundle with a fish tape was a NON issue. No lube required. Don't forget to add stress relief of some sort such as what CD supplies with their VHF antenna/coax kit. Also, you may want to think about using the zip-tie/tie wrap method to keep the wires/cables from banging around inside your mast. (just a thought)

RickR
Jamestown, NY
81 C25/SK/SR/Trad #2668
"Vind Dansor"

DavidBuoy
Admiral

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USA
707 Posts

Response Posted - 04/01/2016 : 05:27:59

Yea, I'll just repeat what everyone else has said... Definitely do something to stop the wires from banging around. My biggest regret when I pulled new ones. I plan to live with it until I replace all the rigging next spring.

Captain Rob & Admiral Alyson
"David Buoy"-1985 C25 SK/SR #5053

mdidomenico
1st Mate

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71 Posts

Response Posted - 04/01/2016 : 11:23:51

i just pulled new wires through the mast as well and i do have the internal cable tube. i did not need to grease up the wires at all, they slide through with a pull string without issue.

but if you really want to grease them, lowes or home depot sell cable grease in the electricians tools area (at least in lowes they do). if not as said previously any electrical supply house will have it as well.

Voyager
Master Marine Consultant

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USA
5231 Posts

Response Posted - 04/03/2016 : 09:51:32

I like silicone spray rather than grease, but that's my preference. I find that it doesn't pick up as much dust and dirt as grease. And after a while it dries out but doesn't get sticky. I spray it on the wires and rub it in with a cotton rag.

Bruce Ross
Passage ~ SR-FK ~ C25 #5032

Port Captain � Milford, CT

smosh
Deckhand

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USA
8 Posts

Response Posted - 04/19/2016 : 06:10:05

I'm planning on replacing the wire and adding an anchor light to the top of the mast. Right now, the electrical ends half way up at the...steaming light?...how are people getting 'new' wire up to the top of the mast?

i could probably also replace the coax for the VHF...that would give me a pull. But i didn't want the extra expense of new vhf cable...

Hm...fish tape from the top to the steaming light, take off the fixture, attach tape to wires through hole (if there's much of one) attach new wires to bottom of old...pull up. Hm.

1979 C25 - Hull #1000

Currently "Phoebe"

jaydon
Navigator

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USA
156 Posts

Response Posted - 04/19/2016 : 06:41:38

Hi
I am doing it tomorrow. I bought the cable from CD which has the splice at the steaming/deck light and then continues to the masthead.
Ours has the tube for the wires, so when we pull the old one out, hopefully can attach the new one to pull down.
There is also the option of a tag line. We'll see which works.
We're also doing a new VHF coax. That will have to be top down so that we can keep the factory connection at the antenna and then one of the new Shakespear connections at the deck.
I'll post when it's done to let those interested know how it all went.
Jay

Jay
South County RI
Cat 25 SR/FK/Trad
#5645
Wind Dancer

jaydon
Navigator

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USA
156 Posts

Response Posted - 04/21/2016 : 14:02:55

Hi all
Well, just got through with running the wires. What a job.
First could not the old one pulled down. Had to remove the tube that thye anchor light is on. Turns out the factory had the wire tied off in the tube.
The two screws holding the tube on were corroded and had to drill off the heads.
The VHF bracket was drilled and tapped into the masthead. Drill those off, also.
Got the masthead off. Used power pro braid for tag lines.
Got the old wire pulled out the bottom. Getting the new wire up the mast was tricky. First getting the wire up to the tube and inside it. Then, pull the top, then the wire for the steaming, then back to the bottom of the mast. Trying to pull the wires evenly was fun. The top was easy once the tube was off; the steaming light wire was fun getting out the really small hole in the mast.
New VHF was the opposite. Pulled it down from the top.Cut the fitting off the bottom of the cable and fed that through the hole. I wanted to keep the factory fitting at the top.
Then pulled it through the bottom of the mast. Then you have to reach up the mast to get the wire through the tiny hole.
Using a Shakespear fitting at the base.
All-in-all, a real fun task. But all the lights now work. LEDs at the anchor and steaming.
Anchor light is new and just replaced the lens on the steaming light. Got a good deal on a stern light and used that lens.
Hope this is helpful for anyone who will be doing it.
Jay

Jay
South County RI
Cat 25 SR/FK/Trad
#5645
Wind Dancer

Ape-X
Admiral

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USA
662 Posts

Response Posted - 04/22/2016 : 03:18:57

for those w/o a wire conduit, use short sections of water pipe insulation and tie off with 2-3 wire ties rotated 180 or in case of 3 ties, 120deg apart. Leave the tails on the wire ties which act as whiskers, holding the wiring away from the sides. Did that with my C25, never a clang.

s/v No Worries, O'Day 28
PO Moe'Uhane - C25 SR/FK #1746

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