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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.
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.
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.
Dredging this up. I have used most of the solutions suggested, but it seems to me a double-flanged rubber grommet makes an ideal chafe guard. A supply of grommets like this https://www.mcmaster.com/9600k66 in 1/2" - 1.75" hole diameters would seem ideal for running wiring, plumbing hose, propane lines, etc.
But I can't seem to find them anywhere for any bulkhead thicker than electronics/aircraft/sheet metal purposes.
Thanks, Chef. Happen to remember which ones specifically? I imagine a C&C 35 also has many 1/2" or thicker bulkheads. I only see 1/4 max slot width at MSC.
Ok, I had one more thought: does anyone have any idea what recently built boats have in this regard? I realize all my experience, and most of what I see on various DIY owner blogs, is boats that pre-date these kinds of construction standards. My 70's era boats' have survived 40 years with zero chafe protections. The propane locker copper tubing exit hole on one boat was gooped with caulk, that's about it.
If you have a newer boat, or have recently poked around or worked on a newer boat, which presumably also need wire and hoses to pass through bulkheads at least 1/2" thick, what chafe protections do you see? ABYC and other boating codes I've seen are rife with "...must be protected from chafing..." wherever it's remotely applicable, so surely some fastidious builders are doing this. And if so, how?
I mostly see wire loom, with hold downs, or plastic tube chases for long runs. That's not a complete view, just anecdotal observation.
Also keep in mind, many systems, even on brand new boats, were not installed by the manufacturer. Rather, they were commissioned by the dealer with local trades.
The key is to limit the movement and friction... that is what chaffs or wears things down. Well secured cable ties which prevent the wires from moving or vibrating and rubbing will do the trick. You don't necessarily need a grommet...
Watch where and how you attach those zip ties, however. We had one holding our engine control wires on their way forward that the original builders had screwed into the cored hull under the quarterberth. Nice and dry there, right? Twenty years of condensation on the cold wires and any splashes making their way down the wires from the control panel in the cockpit led water directly down to the screw and from there into the hull. We ended up with a 2’ diameter patch of delaminated balsa core that was not fun to fix.
I use McMaster-Carr (mcmaster.com). They have practically everything and shipping is extremely quick (for me it's next day).
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