Above deck waterproof power connectors

[Astronomertoo]

Hello all,
Among other major work I will be doing on my 1975 CD25 retirement refurb project will be replacing all the mast wiring and all the worn out nav (and intererior) lights with new better fixtures, with LEDs. I have been following the related postings here. There is not a good fixture or foot of good wire left on my boat, so I will be starting from scratch. I had worked in and knew the market for all the professional offshore, power and oceanographic underwater (and above) waterproof wiring connectors but those products are overkill and way too expensive for a small sailboat. I want to find and use removable, plug-in separate waterproof connectors for my mast wiring at the deck interface at the bottom of the mast, and for connecting solar panels, and have not found any that looked truly waterproof for the marine environment. The connectors must allow for disconnection of the mast lighting above the deck, for dropping the mast on its tabernacle for travel. The tabernacle arrangement does not allow room to simply stuff the spliced connections up in the small mast section on the old CD25, so the connections must be external. I will add a below deck JB in the head area, and run new cables out clam-type water seals to above deck. I am not interested in splicing and heat shrinking often used connections, which is ok for the permanent bow and stern lights but not the mast wiring. The mateable connectors I seek should have good water tight seals to prevent salt water intrusion. The offshore variety often utilize silicon grease to help prevent corrosion on the conductor pins. I have researched this subject and was at the St Petersburg (FL) Marina boat show yesterday and looked for vendors regarding this subject and found none.
Most of the boats I have helped with have had corroded wiring in these locations for lack of a good connector.
Does anyone here have any suggestions for what has been working for them?
I will share what I learn.
Thanks
Bob C

[moctrams]

I have used these trailer light connectors for years and they have proven to the most reliable for me.

http://www.westmarine.com/buy/west-mari ... 8--7066095

[Astronomertoo]

I have used these trailer light connectors for years and they have proven to the most reliable for me.

http://www.westmarine.com/buy/west-mari ... 8--7066095

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I agree with using these cheap trailer connectors, especially with low amperage LEDs. The 4 conductor connector is handy for the local sealed connections if performed inside the mast, and below deck, with all connector pigtails protected from salt water. I would use a silicone lube for this to keep the salt from corroding the metal connections. I also believe there are heavier conductors like 14 awg available but have not found them. This connector will operate 3 switched light fixtures with a common return which would take care of the deck light, steaming light, and anchor light. If you wanted to use a 3 color masthead combo light and/or a strobe it would require an additional 3 conductor connector, for masthead RGW running lights, strobe, plus the 3rd wire for common return. This is a perfectly good solution, and I might do it too, but I am still looking for something like a plastic sealed circular milspec connector. With new 4 conductor marine cable the flat connector will be the weak link, amperage wise. BTW, the hole under my mast into the head area below is not a good place to run the wires, or the antenna coax, and is pretty bad, even if I were not using a hinge plate. Therefore any cables (and VHF coax) will exit the mast thru a rubber seal about 4 in above the hinge plate. I will also run new better coax cable for the new antenna with better shielding, and larger center conductor, with a soldered connector, anti corrosion lube, and Scotch 33+ tape wrapped around the connection joint.
Bob C

[tjr818]

There are many ways to pass wires through the deck yet keep things waterproof, I prefer the "candy cane" approach with PVC pipe. There are several posts on this.

[Steve Laume]

Why make the connections above the deck? This is one of the harshest environments in existence for wire connections.

On Raven, I use Blue Sea clams for the deck penetrations and then make the connections on buss bars below the deck where they are out of the weather and easily accessed. The radar buss is housed in a metal connection box mounted on the head bulkhead and the rest of the wires are on an unshielded buss bar Velcroed to the underside of the coach roof in the little access hole at the base of the mast. Those little clams are very neat and tidy as well as weather proof. It is a simple matter to break the connection and then pull the wires when the mast needs to come down. If you get a blank insert it can be put in for winter stowage when none of the wires are in place.

I always leave a good bit of extra wire in a loop so the ends can be trimmed to provide fresh conductor in the event of some corrosion at the end of the wire. This loop is tucked up and out of sight between the liner and the hull as well.

Any connector that is left out in the weather becomes a weak point in the system, Steve.

[Keith]

I also run the wires through the deck to terminal block(s). However I simply stuff bits of paper towel between the wires and the holes in the deck. Push the bits down a 1/4 inch or so then squeeze in a little white 4200 around the outside of the wires and between them and make a little flange on the deck have a perfect watertight seal. It actually look quite nice as well. A putty knife and small screw driver in the fall and the wires are out in 5 minutes. Every deck mount connector that I every used failed in one way or another. The 420 has never leaked a drop of water through the deck.

[Andy Denmark]

Here's a link to a source for Dri-Plug connectors. These are made to MIL / NASA specs and come in a variety of pin configurations. I've used them for years. They come from England and are pricey but they work well, are totally weather proof (including UV), and absolutely seal thru-deck connections.

http://www.boatwide.es/english/encatalo ... ctors.html


Hope this helps.

Andy Denmark

[Astronomertoo]

Here's a link to a source for Dri-Plug connectors. These are made to MIL / NASA specs and come in a variety of pin configurations. I've used them for years. They come from England and are pricey but they work well, are totally weather proof (including UV), and absolutely seal thru-deck connections.

http://www.boatwide.es/english/encatalo ... ctors.html
Hope this helps.
Andy Denmark

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Thanks Andy,
I am looking for either in-line waterproof connectors, or bulkhead connectors. I took a quickie look at the info and these are inline, which means I would still bring the cables out of my small mast, and out of a clam seal on the deck, then mate in air. I like the idea of solder teminations, and o-ring type sealing with silicone gel inside. I will look to see if there are some available with 5 or 6 pins also. I am not in a rush, and have plenty of time to research this.
Thanks again
BobC

P.S. Merry Christmas to all

[Andy Denmark]

Hmmm,

All the Dri-Plug connectors on my boat are bulkhead (read deck) connectors --- no inlines at all.

Maybe you didn't look at them all?