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Catalina/Capri 25/250 Sailor's Forums

Catalina 25 Specific Forum

panel to mast-base re-wiring

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rbpc25
1st Mate

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USA
86 Posts

Initially Posted - 07/01/2016 : 05:22:09

hi all
new-to-me C25
corroded/cruddy wires leading to mast base
clipped off and barely protruding through deck opening
(wiring running up the mast is good - lights work when hotwired)
no visible wires running below deck
they must be in chases between the lining and the deck
how do folks re-run those lines??
thanks!
Rolf in MA

Rolf in MA
C25 #4959

Edited by - rbpc25 on 07/01/2016 05:24:00

rbpc25
1st Mate

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86 Posts

Response Posted - 07/01/2016 : 05:23:13

(sorry, that topic title is inaccurate - anyone know how to edit?)

Rolf in MA
C25 #4959

sethp001
Mainsheet C-25 Tech Editor

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814 Posts

Response Posted - 07/01/2016 : 08:15:39

quote:
Originally posted by rbpc25

hi all
new-to-me C25
corroded/cruddy wires leading to mast base
clipped off and barely protruding through deck opening
(wiring running up the mast is good - lights work when hotwired)
no visible wires running below deck
they must be in chases between the lining and the deck
how do folks re-run those lines??
thanks!
Rolf in MA

There is not a chase, but space between the interior liner and the hull, through which Catalina ran wires when building the boat.

I'm not sure if my boat had already been rewired before I rewired it, but in my case the wires from the mast are visible under the side decks inside the cabin. If you lay down on the port settee and look up, do you see a bundle of wires under there? If so, you could try the same method I employed: you butt your new wire up to the old wire, wrap the butt with electrical tape, and then gently pull out the old wire from below, which will pull the new wire along with it. This method works best if you have another person up on deck gently pushing the new wire down while you're pulling the old wire out from below.

If you don't see wires in the cabin under the side decks, I doubt this method would work to pull the wire from the deck all the way back to the electrical panel.

Seth
"Outlier" 1987 Catalina 25 SR/SK/Traditional Interior #5541
"Zoo" 1977 Morgan Out Island 30
"Nomad" 1980 Prindle 16
"Lost" 1988 Catalina Capri 14.2 (sold - yay!)
"Marine Tex 1" Unknown Origin POS 8' Fiberglass Dinghy
https://whichsailboat.com/2014/07/27/catalina-25-review/

Voyager
Master Marine Consultant

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USA
5358 Posts

Response Posted - 07/01/2016 : 14:25:40

This is one of the trickiest parts of rewiring our boats.
Catalina simply put the wire harness sandwiched in place when they were laying up the boat so there's no cable chase or tube to route the cable.
Some people have had success pulling the old wire through, others have not. (I was lucky)
Once you reconnect the wires (if you butt splice them), then you've got to route the harness to the switch panel.
Most people route the cable down the back of the bulkhead in the head area, then up along the hull deck joint on the port side from the head, passing along-side of the main salon seating area, then into the "fender locker" (aka the dumpster) behind the power panel.
It doesn't hurt to run one or two extra wires in the cable, just in case you want to add spreader lighting, a fan or TV on the bulkhead or add a stereo somewhere near the head. You don't have to connect up the extra cables now, but they'll be around in case you need them.

Bruce Ross
Passage ~ SR-FK ~ C25 #5032

Port Captain � Milford, CT

offshoreaccount
1st Mate

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USA
71 Posts

Response Posted - 07/01/2016 : 16:09:49

Before you rewire, are you sure your deck connector isn't at fault? You only need 1/3" sticking out for a connector.

Offshore Account, 1977 Hull #243. SR, SK

rbpc25
1st Mate

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USA
86 Posts

Response Posted - 07/01/2016 : 16:15:46

lame - how hard would it have been to sandwich in some tubing around those wires?

so no one has had any success pulling *new* wire through using the original wire as a 'lead'? we have to wire outside of the hull/liner sandwich?

it does feel quite 'stuck'

(thanks for all the replies!)

Rolf in MA
C25 #4959

rbpc25
1st Mate

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USA
86 Posts

Response Posted - 07/01/2016 : 16:17:40

yes, all 3 leads coming through were almost completely severed at deck level - one little pull and all the 6" tails popped off - needs new wire, unless I can somehow splice 3 lines inside a 1/4" hole...

Rolf in MA
C25 #4959

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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.