Mast wiring

[Lee Kaufman]

Problem with the mast/spreader light on my CD 25. Took the fixture down and checked the lights. They are OK. Installed mast steps so it didn't take a gang to get me up the mast to work on the problem. Today I went up and checked the wiring. It's old and brittle. The spreader wire has power but the mast light doesn't. Check at the base of the mast through the access hole in the cabin. Both wires have power here. Problem has to be somewhere in the mast.

OK. I don't want to, but I will have to pull the wires and replace them. Attached a line to the wire at the spreader and went to the cabin to pull the old wires down. They won't pull! The wires seem to be held in place by some kind of caulk. Now I can't get the wires down or the power up.

Has anyone had experience with this problem? Any ideas about what was used to fill the hole the wires go through? Is this original installation or has someone replaced the wires? Is there any way to deal with this without unstepping the mast? I really don't want to do that.

[barfwinkle]

Lee

It is possible that the wires in the cabin are glassed into place. I think it is a requirement of the American Boat and Yacht Council (ABYC) which provides guidelines for the construction of recreational vessels. Now, when did that start I am not too sure, but it is possible.

The wiring on my 1975 Catalina was glassed to the cabin liner.

I dont know for sure if what I am saying is 100% or not, but it is possible. Sorry I dont know much about the 25s so I can suggest how best to approach the problem.

Good Luck

[Ron M.]

use a continuity tester on the wires from the cabin top to the light. That will tell you if the wires will allow current to pass. I suspect one or both have broke/chaffed the insulation, most likely where they exit the mast and go to the light fixture. I had this situation on my boat prior to replacing all the mast wiring.........just one probability.
Does your mast have a conduit in it for the wires ? I can't see how caulking would stop you from pulling the wires down with a good hard yank,(whats to lose ?)- tie a sturdy messenger line before pulling. They may be wrapped around a screw or rivet somewhere along the way. In any event much easier to deal with when the stick is on saw horses. Cant you just bypass the old stuff and snake new wires down the mast for now.......then get the old wire out when the boat is on the hard ?
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Durango

[Jim Davis]

Having owned a 25 and now having another one in my back yard. Your best bet is to drop the mast. The wires are caulked into the step, originally with Dolphinite, but at this time who knows what is there. There is also a plug, or two in the mast to make it possible to separate the connection when the mast is lowered. Trying to yank this out will only compound your problem and leave the plugs laying in the base with the old wire still in the stick. Getting the mast down and up isn't that difficult and makes the job fairly simple. There wasn't any conduct in the mast to prevent wire slap, it just hang from the light. When you run in the new, put three wire ties every couple feet to prevent slap and give you quiet at night when anchored. You will also want to put a new plug on the wire that can be stuffed into the mast when you raise it. Cape Dory used separate wire pairs for the two bulbs in the fixture, but you can combine the negative wire and use three conductor for your replacement in the mast.

Running new wire in the cabin is a different story. Here the wires are between the headliner and the cabin top. I think the consensus is if they are bad, you have to cut them short and find new ways to route and hide the wire. I don't know of anyone who has been able to pull new through the inside of the boat. Above the deck it is easy, below deck wiring is best done during the week when there are no ladies, children or preachers on the pier.

[Lee Kaufman]

Thanks, Jim.

That sounds exactly like what I encountered. There is a gummy white stuff holding the wires in place.

I am really concerned about the idea of lowering the mast. The boat is not in a good place to do that. I guess the best thing would be to have the boat hauled and the mast lowered. Something that I was trying to avoid.

The wiring from the fuse panel to the mast is OK. At least that is something.