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Catalina/Capri 25/250 Sailor's Forums

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Mast Re-wiring

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Cate
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Initially Posted - 04/22/2008 : 10:35:30

I just got the mast harness re-wire kit from CD and am going to attempt to do it on my own. Our mast has been in a shed all winter at our marina and I can have the guys lay it out to work on it. Does anyone have any recommendations for doing this job? I am pretty good at electrical stuff. (Rewired the deck connector and inside to a new panel with 4- plex). I'm wondering how I am going to get the wire out for the steaming/deck light and then bring the rest up for the anchor light?

1983 C-25, Standard rig, swing keel

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Dave5041
Former Mainsheet Editor

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3758 Posts

Response Posted - 04/22/2008 : 11:20:15

Two long strings - tie one to the masthead wires and one to the steaming light wires and mark them. When you pull the wire bundle you transfer the strings to the appropriate wire sets of the new bundle and progressively pull them back.

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Cate
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Response Posted - 04/22/2008 : 11:36:39

<blockquote id="quote">quote:<hr height="1" noshade id="quote">Originally posted by Dave5041
 Two long strings - tie one to the masthead wires and one to the steaming light wires and mark them. When you pull the wire bundle you transfer the strings to the appropriate wire sets of the new bundle and progressively pull them back.
<hr height="1" noshade id="quote"></blockquote id="quote">
Thanks Dave.
Questions: How do I pull the new wire bundle up inside the mast?
Assuming I have two different strings attached to the steaming and anchor wires, how do I pull the steam wire out of the hole in the mast?

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dmpilc
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Response Posted - 04/22/2008 : 13:07:09

It sounds like you tie the strings (heavy twine?) to the wires at the masthead and steaming lights before you pull the old wires out of the mast. When it is all the way out of the mast, you transfer the strings to the appropriate wires on the new wire harness and use the strings to reverse the process, pulling the new wires up the mast to their respective positions. Just my guess!

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Cate
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Response Posted - 04/22/2008 : 13:23:17

<blockquote id="quote">quote:<hr height="1" noshade id="quote">Originally posted by dmpilc
 It sounds like you tie the strings (heavy twine?) to the wires at the masthead and steaming lights before you pull the old wires out of the mast. When it is all the way out of the mast, you transfer the strings to the appropriate wires on the new wire harness and use the strings to reverse the process, pulling the new wires up the mast to their respective positions. Just my guess!
<hr height="1" noshade id="quote"></blockquote id="quote">

Makes sense. I get it now. Sounds like it may be easier than I thought, especially with the mast laying nicely on some saw horses.

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JohnP
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Response Posted - 04/22/2008 : 13:23:49

Yes, that's right. When Dave says "pull the wires", he means remove the wires all the way.

Make sure to use good heavy string. I would recommend pulling down through the base of the mast, instead of through the small hole near the base. Then "hoisting" the new wire harness up through the base of the mast. It's easier than pulling through a little hole. Finally, when the wires are in position, inserting the bottom end of the harness outward through the mast hole near the base, then attaching the black rubber grommet around the wire, and cutting excess and attaching to the through-deck connector.

I did this last month, but there was no wire to the anchor light, so I ran a string from the top of the mast to the steaming light hole using a steel drill bit taped to string and a powerful 3" magnet. That method, or an electrician's snake, would be your backup plans when the string breaks.

There had been a hole near the mast head, but I needed to drill it out to 1/2" to fit the black rubber grommet (in the CD harness kit).

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JohnP
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1520 Posts

Response Posted - 04/22/2008 : 13:30:20

Just remembered --- pull both strings up and out through the steaming light hole first. Bringing them up from the base simultaneously might avoid harness tangles. Then pull the string for the masthead back into the hole and up to the top.

It's easy.

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Dave5041
Former Mainsheet Editor

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USA
3758 Posts

Response Posted - 04/22/2008 : 13:37:12

Braided nylon or dacron for laying level lines in construction is cheap and strong. Walmart, Lowe's, et cet.

I haven't done it on my Cat, but getting by the spreader compression tube on my Clipper was the only part requiring patience.

Edited by - Dave5041 on 04/22/2008 13:41:31

dlucier
Master Marine Consultant

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Virgin Islands (United Kingdom)
7583 Posts

Response Posted - 04/22/2008 : 14:39:28

You may want to consider employing some sort of noise abatement technique to prevent the wiring from slapping around inside the mast.

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Cate
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Response Posted - 04/22/2008 : 14:46:08

<blockquote id="quote">quote:<hr height="1" noshade id="quote">Originally posted by dlucier
 You may want to consider employing some sort of noise abatement technique to prevent the wiring from slapping around inside the mast.
<hr height="1" noshade id="quote"></blockquote id="quote">

My current wires don't slap around inside. I'll have to investigate.
What are the latest noise abatement techniques being used for this project?

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