Join Date: Sep 2011
Location: Dolphin Beach, B.C.
Thanked 18 Times in 18 Posts
Rep Power: 4
Re: Ideas on securing wires inside mast?
I just did this job yesterday.
I had a few things going for me though.
I have 3/4" foam lining the inside of my mast that goes up beyond the steaming light.
This foam was put there for four reasons.
One, to quiet the halyards.
Two, to hold the wires still as the wires are routed up between the mast and the foam.
Three, to help prevent shafing of the wiring.
Four, it helps to reduce condensation on the mast.
This has worked well for over 30 years and if it weren't for the upgrades I wanted to do it would probably have lasted for many more.
The advantage I had was I was able to insert the 1" sched 21 pvc up the mast in between the mast and foam, leaving the original foam in place.
I cut the end of the pvc on an angle so it would pass up the mast easier. With the foam going almost 3/4's of the way up the mast I did not have to rivet it all the way down. I riveted it about 1/3 of the way down and let the foam hold the rest of the conduit still. I did add a few rivets at the base of the mast and above and below the steaming light.
I also extended the conduit so it is flush with the bottom of my mast. The conduit sits on the mast step rather than relying on the rivets to take the weight. I used 90 degree pvc "T"'s for wire access at the steaming light and where the wires exit the mast. This gives me a full 1" access hole without compromising the conduit's structure.
Took me longer to measure, cut and glue the pieces together than it did to push it all the way up the mast and secure it with a few rivets.
I now have a new anchor light and wire, new vhf antenna and coax, new wires for my wind machine, new wires for my steaming light and deck lights and room for a radar data cable in the future.
My new genoa halyard will be tricky to get right. I cannot have it going around my Nav-tang cross bolts. It will need a clear run through the mast. Wire halyards can cut through Nav-tang cross bolts and bring down your mast.
When I am done I will have 6 new internal halyards, all new mast wiring and new "USCG" approved LED's.
All of my outside lights are now USCG approved LED's.
I have a thread going about this project. I have one more day of rigging left to do and then my mast is ready to go back in the boat.
I'm taking pictures and I will post them.