getting a wire run inside the mast

A forum for discussing boat or trailer repairs or modifications that you have made or are considering.
Post Reply
User avatar
cmeperform
Engineer
Posts: 107
Joined: Fri May 23, 2008 11:12 am
Sailboat: MacGregor 26M
Location: Tarpon Springs Fl

getting a wire run inside the mast

Post by cmeperform »

Anybody have any good ideas on how to do this since styrofoam is crammed full inside it?I would like a wire run from the bottom to the top of the mast.
User avatar
bubba
Captain
Posts: 896
Joined: Fri Mar 21, 2008 11:04 am
Sailboat: MacGregor 26M
Location: Richland,WA Columbia River Lake Wallula "INSPIRATION" w/70 suz. 9' Merc dingy
Contact:

Re: getting a wire run inside the mast

Post by bubba »

Here goes : You need 2 - 10 ft lengths of 3/4" pvc electric conduit. Cut teeth about 3/4 inch deep in the smaller diameter end of one piece (I used a small hack saw to cut teeth ), drill a small hole in the end without teeth to put a screw driver thru to use for turning the conduit and cutting your way thru the foam. Remove the mast top and bottom caps start drilling from the top using WD40 A LOT for lube. Drill in a location you won't run into a bolt. Use pvc glue to connect the conduit pieces, it should dry. Pull out often to empty the chuncks of foam. You will want to leave the pvc in when finished. I used a long piece of house wire to push thru the conduit and pull your wire thru. A pop rivit gun is needed to replace the top cap.

We mounted an LED anchor light that meets the coast guard regs on the cap, it uses .02 watts.

Good Luck and Happy Hollidays
User avatar
cmeperform
Engineer
Posts: 107
Joined: Fri May 23, 2008 11:12 am
Sailboat: MacGregor 26M
Location: Tarpon Springs Fl

Re: getting a wire run inside the mast

Post by cmeperform »

Sounds as good of way as any.Thank you. :D
User avatar
cmeperform
Engineer
Posts: 107
Joined: Fri May 23, 2008 11:12 am
Sailboat: MacGregor 26M
Location: Tarpon Springs Fl

Re: getting a wire run inside the mast

Post by cmeperform »

The styrofoam is just in the top half of the mast.
User avatar
bubba
Captain
Posts: 896
Joined: Fri Mar 21, 2008 11:04 am
Sailboat: MacGregor 26M
Location: Richland,WA Columbia River Lake Wallula "INSPIRATION" w/70 suz. 9' Merc dingy
Contact:

Re: getting a wire run inside the mast

Post by bubba »

Yes, the foam is in only the upper section to allow flotation in the mast, about the top 16 feet or so, but it does move when you are drilling and pushing thru the foam. From the stock running light down the mast is empty except for elect wires so carefull don't get tangled up and cut the existing wires.
User avatar
cmeperform
Engineer
Posts: 107
Joined: Fri May 23, 2008 11:12 am
Sailboat: MacGregor 26M
Location: Tarpon Springs Fl

Re: getting a wire run inside the mast

Post by cmeperform »

Thanks,It's done.I'm through..Where can one find a new kind of top hat?
User avatar
Russ
Admiral
Posts: 8302
Joined: Thu Oct 11, 2007 12:01 pm
Sailboat: MacGregor 26M
Location: Bozeman, Montana "Luna Azul" 2008 M 70hp Suzi

Re: getting a wire run inside the mast

Post by Russ »

cmeperform wrote:Thanks,It's done.I'm through..Where can one find a new kind of top hat?
A new "kind" of a new top hat?

Mine was cheap plastic but careful drilling I was able to reuse it with new pop rivets. If you broke yours, I'm sure BWY has parts.
http://www.bwyachts.com/

BTW.. here's a thread on this topic (a bit too late I suppose). I was able to poke a fishtape between the foam and the aluminum. Also, I pulled a string along with my coax in case I needed to do this again in the future.
http://macgregorsailors.com/forum/viewt ... it=antenna
User avatar
cmeperform
Engineer
Posts: 107
Joined: Fri May 23, 2008 11:12 am
Sailboat: MacGregor 26M
Location: Tarpon Springs Fl

Re: getting a wire run inside the mast

Post by cmeperform »

yes, I'm in the market for a new tophat & also new digital mast light.One that uses less battery power.Guess I will make a new tophat to replace the cheap junk they sold us. :D Aluminum
User avatar
bubba
Captain
Posts: 896
Joined: Fri Mar 21, 2008 11:04 am
Sailboat: MacGregor 26M
Location: Richland,WA Columbia River Lake Wallula "INSPIRATION" w/70 suz. 9' Merc dingy
Contact:

Re: getting a wire run inside the mast

Post by bubba »

We found our anchor light for the mast head at Fisheries Supply. It is an LED light that is light and small and mounts on top of the stock mast cap and only uses only .02 watts.
User avatar
cmeperform
Engineer
Posts: 107
Joined: Fri May 23, 2008 11:12 am
Sailboat: MacGregor 26M
Location: Tarpon Springs Fl

Re: getting a wire run inside the mast

Post by cmeperform »

Good deal,I'm replacing all my lights to the digital low watt kind.If I find something along the way,I will share it on here.Thanks again
Post Reply