What do people use to prevent wire chafe? - SailNet Community
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post #1 of 8 Old 04-02-2018 Thread Starter
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What do people use to prevent wire chafe?

I'm running a lot of new wire as well as reorganizing a lot of existing wires.

Some of the previous owners of this boat played it fast and loose with wire runs. Literally squeezing wires through bulkheads wherever they would fit. These are a priority for me to replace so I can properly route them to ensure they don't chafe through and cause me problems.

Again, I may be running up against my impatience with search engines, but I'm not finding a material to buy to provide chafe protection for wire (such as where it goes through bulkheads). My plan is to epoxy in a short section of PVC pipe when I make new holes, but I'd still want something to keep the wire from chafing on the edge of the pipe. The few places I've found where it seems to be done well appear to have used short pieces of rubber hose, but I'm worried that the wrong kind of hose will have reinforcing made of wire or some other material that will actually be just as bad.

What do people use for this sort of thing?
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Re: What do people use to prevent wire chafe?

Rubber grommets. They come in many different diameters as well as thicknesses.

Last edited by seabeau; 04-02-2018 at 06:39 AM.
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Re: What do people use to prevent wire chafe?

Clear vinyl hose, Split it, cut to length.
Can also be used to form a grommet if the material is not too thick.
Plumbing dept at big box...
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Re: What do people use to prevent wire chafe?

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Clear vinyl hose, Split it, cut to length.
Can also be used to form a grommet if the material is not too thick.
Plumbing dept at big box...
Yes and no... this stuff gets brittle and shar edges of the cut hose are hardly better than the hole in the bulkhead.

Split rubber wire grommets and secure the cable with ties on both sides of the hole to stop movement from vibration.

You can also use split wire.

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Re: What do people use to prevent wire chafe?

Low pressure rubber fuel line available at any auto parts store for cheap, standard anti-short bushings from the electrical section of your local hardware store (pack of 35 is usually less than $3), chase nipples from the electrical section of your local hardware store, cut off of non-metallic conduit (deburred), shrink wrap, etc. Lots of good options out there.


https://www.homedepot.com/p/3-8-in-F...5401/100170558

https://www.homedepot.com/p/1-2-in-R...0701/100123708
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Re: What do people use to prevent wire chafe?

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My plan is to epoxy in a short section of PVC pipe when I make new holes, but I'd still want something to keep the wire from chafing on the edge of the pipe.
Sand the pipe to remove the burs and soften the edges.

I did a major rewiring job a few years ago. My favorite method of preventing chafe was trying to eliminate the wire moving by securing it often along it's run. Then use a wire wrap for areas of abrasion concern.

https://www.cabletiesandmore.com/ame...caAicQEALw_wcB

I since discovered the split conduit Sander O posted for a truck wiring project and think it would also be great for boat wiring.
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Re: What do people use to prevent wire chafe?

I've worked on some old boats, and I've never seen hose get hard enough to damage the wire. Any hose without wire. Tougher than split conduit.

Silicon sealant works (in addition) if you need a seal. One of the few on-boat uses.

And secure the wires.
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Re: What do people use to prevent wire chafe?

+1 for SiliconE sealant. Put a glob on where the wire penetrates the bulkhead. This is one of the few uses, if not the only use, aboard.


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