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 Catalina/Capri 25/250 Sailor's Forums
 Catalina 25 Specific Forum
 rewiring mast		  New Topic  Topic Locked
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bouy
1st Mate

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33 Posts
Initially Posted - 08/09/2010 :  16:16:11  Show Profile
Spent the morning in the HOT !!! sun trying to figure out how to pull new wire harness (catalina Direct) thru the mast for anchor and steaming light/deck light. Seems there is some foam in the mast. I don't know how much but I can see it at the bottom and upper parts of the mast. The mast is off the boat so I thought this would a good time to replace the wiring for the lights and coax for the radio. Any suggestions?
81 sksr #1733
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Leon Sisson
Master Marine Consultant

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USA
1893 Posts
Response Posted - 08/09/2010 :  16:56:58  Show Profile  Visit Leon Sisson's Homepage
Re: "<i>...trying to figure out how to pull new wire harness ... thru the mast ... to replace the wiring for the lights and coax for the radio. Any suggestions?</i>"

I use and recommend the thin wall PVC conduit method described in "This Old Boat" by Don Casey. I think the original Catalina installation used 'bow ties' of foam to quiet slapping wires in the mast.

-- Leon Sisson
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calden
Navigator

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USA
194 Posts
Response Posted - 08/09/2010 :  17:02:17  Show Profile
Just did that. Tightly tape 1/8" parachute-type line to the end of the steaming light and the anchor light. Give it a pull test to make sure it's really snug, and make sure you have enough length - more than 30' for the anchor light and -what - 25' for the steaming light. Then pull the old wiring out, and have a helper feed the parachute line in. The foam will come out with the wire - it's likely taped on. Then retape the ends of the parachute cord to the new wiring. I did the steaming light first, and it would have been a lot easier to pull the anchor light wiring first, taping the foam on every 6 or 8' or so.

Don't forget to add strain relief. Catalina Direct suggests using monel rigging wire, tightly taping it with electrical tape to the end of the wire as it's outside the mast at the ends, and then using a screw or pop rivet attach a loop of the monel wire to the mast. I didnt' do this, and have to drop the mast again. I''m sure I'm okay for a year or so, but I want to do it right, so down we go (again...)

Carlos
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Ed Cassidy
Captain

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USA
365 Posts
Response Posted - 08/09/2010 :  17:11:43  Show Profile
I tied a strong nylon string to the old wire both at the top of the mast and at the steaming light and pulled the old wire out the bottom of the mast. It had about 5 or 6 chunks of foam rubber tied to the wire to prevent slapping. On the reinstall, I used three nylon wire ties about every 5 feet and pulled the new wire back into the mast from the bottom using the two nylon lines. It was rather easy with no hangups. The new harness from CD is top notch!
Ed
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captaindave
Deckhand

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USA
2 Posts
Response Posted - 08/10/2010 :  03:58:12  Show Profile  Visit captaindave's Homepage

I sent a wire snake through the mast while it was laying horizontal.Had no obstructions. Good luck skipper. Get out there and sail.
Capt. Dave PEG 2 1986 Cat 25 SK/SR
Sail Free or Die









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redeye
Master Marine Consultant

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3476 Posts
Response Posted - 08/10/2010 :  06:12:36  Show Profile
Thank You ED. I'm looking at the same job soon I expect. Trying to goo over everything in my mind. Looks like the CD harness is sweet. Great price also.

Did you ( or others ) tied a knot in the wire as it comes out of the mast at the top to hold it in Place? How'd you secure it?

I sorry I can't picture the "monel wire" method.
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calden
Navigator

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USA
194 Posts
Response Posted - 08/10/2010 :  07:42:57  Show Profile
The wire is used to secure the wiring so it won't slip back into the mast (as tying a knot would do.) Kind of like this, with the wire securely taped to the wiring harness - like 12" worth. Sorry for the crude word processing diagram.

I couldn't a picture of this on the catalina direct site - maybe I just imagined it, or maybe it's in the catalina direct manual.

CarlPr
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Ed Cassidy
Captain

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USA
365 Posts
Response Posted - 08/10/2010 :  08:13:32  Show Profile
I just tied a knot in the wire.
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redeye
Master Marine Consultant

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3476 Posts
Response Posted - 08/10/2010 :  10:28:19  Show Profile
Yepper, thanks. I've seen the knot in the wire thing used most often, even without a grommet. Thanks Carl. I see what you are saying with the wire.

Details, details.
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JohnP
Master Marine Consultant

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1520 Posts
Response Posted - 08/10/2010 :  11:23:10  Show Profile
I bought the mast wiring harness kit from CD. It's worth it.

What year and style is your C-25? You can put this info into your signature of every posting by adding it to your "profile".
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bouy
1st Mate

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33 Posts
Response Posted - 08/10/2010 :  14:07:48  Show Profile
My boat is a 1980 C25 (Rose of Sharon) sk. Thanks for the tips. I think with info provided I should be able to complete the job. Am also considering replacing the standing rigging while the mast is off the boat. I" sure it's the original (with old style bullet shaped turnbuckles) Has any one used the complete sets offered by CD ?.
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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.