Mast re-wiring info and photos

mcrandall · Post by **mcrandall** » Sat Jun 04, 2011 12:15 pm

I had the same type as Alan and Mariner. Bought it from West Marine last year, opened it this week and took it back. Ordered identical replacement for what I assume to be the OEM mastlight. Gonna put spreader lights up and this is what I'm thinking about:
http://www.oznium.com/marine-led-light

The URL will take you to their 120 degree angle floodlight. They also have a 25 degree angle spotlight. At our spreader height, it casts about a 6 foot circle straight down.

I purchased a red and white of each kind and tried them out in my backyard. The spot is nice and bright. The flood is less so but the area is quite large. I'm very impressed with the amount of light at only about 150 mA for the whites.

These get warm, but not hot. They are designed for underwater use as is. VERY pleased with the customer service and the price is not too shabby either.

I'm going to do more experimenting and let you know how it goes. I've bought a couple of other products from there for interior lighting.

Cheers!

Alanhod · Post by **Alanhod** » Sat Jun 04, 2011 12:27 pm

Yea, I like this. What have you got set up for a mounting bracket?

Photo's of these installed would be real nice to see once you've got it completed. I like the red and white light idea too. Only 150mA, I like that a lot better than a 15 watt halogen, sucking the battery down. This would keep my whole boat power consumption under 200mA with one of these turned on and everything else turned on too. Very nice idea indeed!

Thanks
Alan

mariner · Post by **mariner** » Sun Jun 05, 2011 4:35 am

Mark, I like these too, I'm going to get this and replace the halogen with one of these for now, if I ever change the spreaders to the foil shape, these are going on them. Thanks for sharing the source.

mcrandall · Post by **mcrandall** » Sat Jun 11, 2011 5:06 pm

So I've been plugging along at putting new spreaders on and rewiring the mast. I bought the Dwyer airfoil spreaders like some of the others have. Thought about the sheet metal screws for mounting them, but didn't like the idea of the sharps in there with my new cabling. Then I thought about machine screws and feared the walls of the mast are rather thin to get a decent purchase. Probably OK, but thats me...

So I went with aluminum pop rivets:

You can just see them on the "bottom" bracket. Wiring pigtails are for the LED lights I'm going to string on the spreaders.

Next concern I had discussed with Jeff offline and others had mentioned, was the fear that the pressure of the spreaders might start caving in the sides of the mast. I know someone developed an "exo-skeleton". I decided to go with an internal compression support. I had a chunk of 3/4 aluminum round stock, so I drilled a hole straight through to where each of the brackets would rest. I mounted the first bracket, ran the rod through and cut it off in place. There's enough length for it to rest in place, but I put a dab of epoxy on the end for insurance. I could drill it out, tap and run a machine screw into it, but I'll need to get my worry gene working on that for a while.

Here's a shot of the rod cut flush:

Finally, I put the other bracket in place and riveted it. I terminated the wires with a four pin trailer connector:

I'll be finishing the other side tomorrow, then on to the top of the mast!

Cheers!

Alanhod · Post by **Alanhod** » Sat Jun 11, 2011 7:40 pm

Sweet!

Thanks
Alan

mcrandall · Post by **mcrandall** » Sun Jun 12, 2011 7:33 pm

I finished the install of the wiring for the spreaders. Then I cut the spreaders to size and installed them. Look pretty cool, if I say so myself!

So then I started looking into installing the LED spreader lights. I had a piece of plastic wood that a friend gave me, left over from an outdoor furniture project. I got a large forstner bit and milled out the larger hole about 3/4 the way through, then followed up with a paddle bit to complete the opening. This left a nice step for the LED to set in:

And this is how the LED looks installed in the "housing":

I'm going to see if I can mill the back out to fit nicely against the spreader (that's a scrap of the spreader underneath). I plan on mounting two LEDs side-by-side in each fixture and one fixture on each spreader. Perhaps I'll shape the outside to look a bit more visually pleasing as well. We shall see... More later!

Bhacurly · Post by **Bhacurly** » Sun Jun 12, 2011 7:37 pm

Alan,

That's why I like Fisheries Supply in Seattle... They have most that stuff on the shelf or will maybe have it in the huge basement and will get it out for you. I have to have a shopping list an have done some online research for prices etc... But ya to hold it an see how it's made is cool...

Bhacurly · Post by **Bhacurly** » Mon Jun 13, 2011 8:31 am

Looking great Mark!

Missed that we were on page 2 so just saw your picts. Very nice!

Alanhod · Post by **Alanhod** » Mon Jun 13, 2011 4:53 pm

Nicely fabricated bracket, First Class Mark!

Fisheries Supply in Seattle, you say. I have never heard of it, sounds like fun. Perhaps I have missed a posting somewhere. Or is that were these lights come from? No matter I will have to look into it if your willing to drive the long way across the state to shop there, it must be good!

Bhacurly · Post by **Bhacurly** » Mon Jun 13, 2011 10:53 pm

Alan,

The store is just west of the UW campus...

http://www.fisheriessupply.com/

It's a routine stop every trip over to the big city!

mcrandall · Post by **mcrandall** » Tue Jun 21, 2011 2:04 pm

Well, here's a little more info to keep this thread alive!

I'm done with the spreaders with the exception of placing the LED flood lights. Still stewing on that a little, so I thought I would look into the top of the mast. All my stuff was slapped up there with angle brackets and looked like hell. So I decided to make a top for the mast so I could mount everything a little neater.

I asume all our mast heads look similar, this is what I'm starting with.

I have an antenna, anchor light, windex and a couple of LED spotlights to mount.

Here's what I cam up with:

I took 2-inch aluminum angle bracket and made a "C" bracket out of it. I'll be drilling through the skirts and the block tabs of the mast head to mount it.

I located the two spotlights under the bracket and just inside the 45 degree bevels on the skirts. These LEDs lay down a 9-foot diameter spot from the height they're located and will shine on the fore deck and cockpit. Not daylight, but plenty bright to read by. And again, only 150 mA each! Between those and the floods on the spreaders, should be sufficient.

mariner · Post by **mariner** » Tue Jun 21, 2011 5:10 pm

Mark, I like it, clean and neat

skyking · Post by **skyking** » Thu Jun 23, 2011 3:00 am

Mark,

Very nice...

I'm having trouble finding a 4pin connector on west marines web site...Can someone post a link if they come across it?

Thanks guys...

mariner · Post by **mariner** » Thu Jun 23, 2011 4:24 am

I have not been very impressed with any of the connectors that I have seen, since I also will have a coax cable for the radio, I have decided to use a through hull compression fitting called scan strut, you can then just make one hole. I will then make the connection inside either with blade connections or some other type. I'll post photos ASAP.
http://www.scanstrut.com/products/produ ... =Deckseals

Bhacurly · Post by **Bhacurly** » Thu Jun 23, 2011 9:05 am

Looks Great Mark!

Would love to see it all lit up under sail with a full moon behind you!

I would put your strut scan aft of the port/starboard midline of the mast. This will keep it outta the way of your lines coming across the bow when tacking or gybing.

My connector is right in front of the mast and drives me nuts everytime I tack,,, I have to watch and make sure I haven't pulled my connections apart. I use a bungie to keep them close to the mast and give them some support

lecker68 · Post by **lecker68** » Thu Jun 23, 2011 11:34 am

Skyking here is the one from WM 2 pin or 4 pin

http://www.westmarine.com/webapp/wcs/st ... sNum=10615

skyking · Post by **skyking** » Thu Jun 23, 2011 12:05 pm

Thank you..Dont know why I couldnt find it...Thanks a lot

Alanhod · Post by **Alanhod** » Sun Jun 26, 2011 2:23 pm

First rate there Mark. I like that a lot.

How did you get the screws out of the top of the mast that hold the header on? I could not even loosen one of mine so I just worked with the existing holes for wiring.

I'd also like to see your newly fabricated top installed on the mast. I used the same base mount my boat had and built up from there.

Yea, that Coax connector is what stopped me from rewiring my antenna. I'll have to consider it for another season.

Thanks
Alan

mcrandall · Post by **mcrandall** » Sun Jun 26, 2011 6:59 pm

My antenna cable and connectors are due in on Tuesday. Have to see how things fit before I make final holes. Got a pretty neat idea for running the wires and antenna cable up top.

Pictures soon, if it all works out.

Strangely enough, all but one of the screws came out as easy as you please! One seized and the head twisted off. I'll have to retap it and replace it with a larger one. Maybe I'll just use pop rivets.

Any thoughts from the group on using rivets vice machine screws?

Alanhod · Post by **Alanhod** » Sat Jul 02, 2011 11:54 am

Well I can think of one good advantage to rivets. (My Opinion only)

The pop rivet will be made of Aluminum and the mast is Aluminum, so no galvanic issues like you would have with Stainless steal screws seizing in place.

On my mast the base cap of the mast is Pop riveted on with a self sealing type rivet I think. (No hole through the middle when the mandrel is pulled out to deform the buck head. Had my top come off I was going to replace it with those same pop Rivets I have on the base.

Second advantage for me is I am really good at drilling out old or bad pop rivets without damaging the surrounding material. So it would be easy to redo if I ever had too pop the top again.

This is the best shot I have of the base of the mast.

Thanks
Alan

mcrandall · Post by **mcrandall** » Sat Jul 02, 2011 6:36 pm

I'm with you, Alan. I like the idea of all aluminum. And they are so easy to install and remove.

Making a lot of headway with the mast, should have it done this weekend. Next step is to reinstall the keel. That means hauling my rack back around front (much to the apparent displeasure of some of my neighbors

) in order to lift the boat off the trailer. Going to get the bottom paint done while I have it in the air. Topside paint will come after I put it back on the trailer.

I love this project! Helping a friend with auto helm install and house/cranking battery install on his 34-footer. He's teaching me to sail on it as soon as we can get it in the water. Like it, like it, like it!

mcrandall · Post by **mcrandall** » Sun Jul 03, 2011 10:12 pm

Hi Guys! Happy 4th!!!

I need your help here!

I just finished the top of the mast and the spreaders. Here's a couple shots so you can see how they turned out:

As you can see, I replaced the masthead light as well. The two flex conduits house the electrical for the LED spotlights and the anchor light, while the second one houses the antenna coax. Thought I would use this stuff to keep some of the sun rot down.

Here's a shot of the spreaders. I got the Dwyer airfoil type and added some LED floodights:

And here's a couple shots with everything in place. I fired up the LEDs, thats two spots at the top of the mast and 4 floods on the spreaders:

O.K. Here's where I need the help. I'm going to finish the wiring with the same type of conduit at the bottom of the mast. I have a nice 6-pin trailer connector that I'll mount in the deck to plug in to. Probably use a clam-whatever port for running the antenna cable through the deck, or a cassis fitting for a UHF antenna cable, not sure which yet.

Here's my delemma: I need to know where to put them. Right now, the deck has holes and fittings directly in front of the mast step. Do I leave them there? Would they be better on each side of the mast to avoid fouling with the jib sheets?

Here's a couple more shots that show my current rigging on the bottom of my mast. (Keep in mind, I've never sailed her, so I don't know the details of why anything is anywhere!) This first one is obviously the aft, base of the mast (base plate removed.) You'll see the harness I intend to use draped over it.

And this is sort of a shot of the forward side of the mast. You can see the previous holes used on the front of the mast close to the base. Sorry the shot is blurry, to help you identify it, one of the holes still has the rubber grommet in it.

I would like to mount my conduit on the side of the mast, towards the rear. That's the flatest area of the mast, but I can put them anywhere! I'm just too green to know where I need to stay away from when placing them. Don't want to place them right where a line has to go

. So it boils down to: where on the mast and where on the deck.

As always, any advice is most appreciated!

P.S. I plan on painting topside. I'll be re-doing the hardware, etc. By now you know I'm not afraid to cut new holes

.

Alanhod · Post by **Alanhod** » Sat Jul 09, 2011 6:05 pm

Okay, I'm for not making any more holes in the deck. I used the holes the folks before me did in my deck. I used these connectors pictured here. the details of those connectors are in this thread near the beginning. I have no solution at this time. I'm connect my antenna when the right supper cool fix has been invented by some here on the forum and it's posted.

Mcrandall, "A+" grade here my friend. Also I can't take it any more, I'm fully inspired, I'm logging off the forum right now and I'm going to work on my boat. There must be 25 posts here I have not yet read but I can't wait a moment longer, I'm off to the boat! Inspirational fabrication and work indeed!

Thanks
Alan

lecker68 · Post by **lecker68** » Sat Jul 09, 2011 6:16 pm

Mark usually 4 to 10" in front of the mast you are ok because the clew of the jib is well above the deck.

Nicknick32 · Post by **Nicknick32** » Tue Mar 20, 2012 7:27 pm

This place is awesome, Im new here and new to sailing. I bought my first sail boat (chrysler 22 fixed keel) at the end of june last year. I am about to re do the mast and I came accross this site.

Thank you to all the people who have posted and have put up alot of good info for non handy guys like me.

Funny, I cought refrance to Red Green........He lives on his HUGE house boat in my harbour all summer long.........Cool guy.

Thanks again!!!!

CaptainScott · Post by **CaptainScott** » Wed Mar 21, 2012 5:11 am

Welcome aboard Nicknick32! Glad to have ya here!
We must of course see some photos of your boat! LOL!

Again, Welcome!
Scott

Nicknick32 · Post by **Nicknick32** » Wed Mar 21, 2012 8:16 am

Thank you and i will get some photos up soon.

skyking · Post by **skyking** » Wed Mar 21, 2012 2:48 pm

Welcome Nicknick32

Nice to see another fixed keel 22

Alanhod · Post by **Alanhod** » Thu Mar 29, 2012 3:57 pm

Nicknick32 wrote:Funny, I cought refrance to Red Green........He lives on his HUGE house boat in my harbour all summer long.........Cool guy.

Welcome Aboard Nicknick32!

You know what uncle Red always said... "If women don't find you handsome, then they better find you handy."

I'm not sure that handy on my boat counts. Gosh I hope it does.

Thanks,
Alan

Nicknick32 · Post by **Nicknick32** » Thu Mar 29, 2012 6:36 pm

LMAO thanks....too funny.

Chrysler Sailors Forum

Mast re-wiring info and photos

This place is great

Re: This place is great