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Deck plug wiring

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SteveG
1st Mate

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51 Posts

Initially Posted - 08/18/2004 : 16:15:34

Hi All,

I have a problem with the wiring to the foredeck and masthead lights. After a little troubleshooting I found that the wires coming up to the deck plug are broken due to corrosion and there isn't enough slack in them to trim the insulation back and resolder them to the plug.

I think I know the answer to my next question, but I'm going to ask it anyway. Is there a way to feed more wire up to the deck plug without taking out the mast support and bulkhead? I'm keeping my fingers crossed, hoping someone has a solution. I really don't want to step the mast to do the work if I can help it.

Thanks,

Steve Gravel

Portsmouth, RI
C25 - 'Lady Jane'
SR/FK

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Frank Hopper
Past Commodore

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Pitcairn Island
6776 Posts

Response Posted - 08/18/2004 : 16:45:37

splice

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RichardG
Admiral

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USA
990 Posts

Response Posted - 08/19/2004 : 01:53:35

Steve:

The wires run between the deck and the liner, thus it's very difficult to get to them. The previous owner of my boat ran new wire from the main panel to the deck connector. It runs through the cabin along the hull/deck joint, and is essentially hidden from view by the little "lip" that sticks down. It goes through small holes drilled in the upper, outside corners of the bulkheads. It is more visible in the head, running along the edge where the bulkhead meets the overhead deck liner, but it looks clean. I'm guessing he drilled the hole through the deck from above (i.e. with the deck connector removed).

I had similar voltage/corrosion problems in the wire to the bow lights and ran new wire for that, except I ran it all the way into the anchor locker along the hull/deck joint.

Good luck.

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SteveG
1st Mate

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51 Posts

Response Posted - 08/19/2004 : 08:02:16

You replied:

<blockquote id="quote">quote:<hr height="1" noshade id="quote">Originally posted by fhopper@mac.com
 splice
<hr height="1" noshade id="quote"></blockquote id="quote">

Thanks for the suggestion, but there is not enough wire to work with at the deck plug and I don't see an easy way to get to the wire from belowdecks. The only options that I can see are; step the mast, pull the mast support post and bulkhead, then splice; run new wires from the power panel and drill through the deck to get to the plug. I was hoping someone else knew of an easier way to fix the problem.

Thanks,

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Bill Holcomb
Admiral

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USA
769 Posts

Response Posted - 08/19/2004 : 09:24:44

Hi Steve,

Your mast wiring problem is a common one. There have been many posts over the years regarding it and solutions. Rickard's reply is the most common solution. Often, the solution will include a new deck plug as well as new wires.

BTW: If you use marine certified wires (tinned), you significantly reduce the chances of corrosion in the future.

Bill Holcomb - C25 Snickerdoodle #4839

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Earl Landers
Navigator

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USA
157 Posts

Response Posted - 08/19/2004 : 11:36:28

Steve,
I also used the method that Richard mentions. That is drilling thru the deck and liner under the existing deck plug and running new wires from the bottom. There was no need to remove either the compression post or bulkhead, nor step the mast, as the new "thru-hole" came out just forward of the bulkhead. I used a small pilot hole to determine exactly where the hole would be and drilled to size.

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RichardG
Admiral

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USA
990 Posts

Response Posted - 08/19/2004 : 12:44:13

<blockquote id="quote">quote:<hr height="1" noshade id="quote">I was hoping someone else knew of an easier way to fix the problem.<hr height="1" noshade id="quote"></blockquote id="quote">

It really wasn't that difficult when I ran new wires to the bow lights, which may be slightly more difficult than running new wire to the deck plug (1 less bulkhead and anchor locker to go through). I would guess that removing the compression post and bulkhead would be considerably more difficult, plus you may have badly corroded wire once you get in there.

Another benefit to running new wire is that it forced me to get into the cockpit locker to better understand and diagram all the wiring behind the main panel, including confirming which old wires that dissappeared into the fiberglass between the liner and deck were now obsolete. I was lucky to find that the wires going to the cabin lights, which also are buried and mostly inaccessable between the liner and deck, are still in acceptable condition, and not causing too much voltage drop. After identifying with certainty the obsolete wires, I cut and capped them.

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ilnadi
Captain

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452 Posts

Response Posted - 08/19/2004 : 15:35:00

Did you guys change the in-mast wiring at the same time you re-wired inside? I would think the mast wiring and fixtures would corrode as fast as, if not faster than, the wiring inside the boat (more exposure).

We will have the mast down for about two days this weekend (moving the boat) and we already have some light issues (the PO thinks the people servicing the inboard re-connected things wrong, we've had the boat for a week and I have not had a chance to investigate). Just thinking we will not have the mast down for another while and may be worth doing as much maintenance as I can while I can.

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Earl Landers
Navigator

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USA
157 Posts

Response Posted - 08/19/2004 : 18:45:53

In my case the mast wiring was in better shape that that to the deck plug. I don't know if the PO had replaced it previously, or if it was in better shape because there is slack in the mast wiring which you can shorten to get new connections. I changed the mast wiring when I added a fordeck light.

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SteveG
1st Mate

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51 Posts

Response Posted - 08/20/2004 : 07:16:16

Thanks for all of the tips. I plan on running new wiring from the power panel and drilling a new hole under the existing deck plug. This will be the easiest solution. The wiring in the mast seems to be okay, I checked it out when I first bought the boat, Spring of last year. The mast was down and I took the opportunity to replace the masthead light. The original one was still installed and it looked like wouldn't have worked even if I had power.

Thanks,

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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.