Investing in paint for my ‘98X

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OverEasy
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Re: Investing in paint for my ‘98X

Post by OverEasy »

Hi Herschel!

Boat wiring really shouldn’t involve soldering at all.

First: Marine-grade wiring is a specialized, stranded, highly flexible cable with tinned copper conductors (to prevent corrosion) and durable insulation (like PVC or XLPE) to resist moisture, heat, oil, and chafing, designed for boats' harsh, vibrating, wet environments, often meeting specific standards like UL 1426, unlike less robust auto or house wiring. Never use solid core wire.

Second: Crimp connectors are the preferred and recommended means of making splices or terminal ends like eye or fork type ends.
Eyes while more secure as they are captured by a screw or nutted post/stud are a bit more time consuming to attach as the screw or nut must be fully removed and reinstalled. Fork type ends are a little less secure in the the screw or nut is loosened sufficiently to allow the fork to be slipped under it and then tightened. Done properly either will work. The higher the vibration area and the greater the importance of the particular circuit one tends to use eye type terminations.
The crimp connectors for boats are now generally insulated with heat activated heat shrink tubing nowadays. After the crimp connection is made the insulating collar is heated to shrink the collar and activate the adhesive which seals the insulated wire/connector interface from moisture intrusion. As the connector insulating collars are generally a bit short many professionals prefer to add an additional length of separate adhesive heat shrink tubing generally at least 3/4 of an inch or more beyond the crimp connection. (One just has to remember to slip the extra heat shrink tubing onto the wire before making the crimp connection.) A electricians heat gun is the the preferred means to apply heat rather than an open flame.

A marine grade terminal strip is the general go to when routing wires that need junctions. Say when one lead is divided into multiple sub circuits such as for lighting circuits.

A marine grade buss bar is the preferred means to take a primary lead, such as the positive output from the battery and then distribute it to a host multiple circuits.

As a rule one should maintain one to two connections to a given terminal/bus screw/stud. Avoid multiple connections to a stud or screw as multiples will tend to lead to self loosening connections.

If a wire line requires a mid run disconnect there are shielded male/female crimp connectors for that purpose. A general rule is to have the side that can supply positive electrical power be the shielded female connector. That way one can avoid potential shorts by inadvertent contact with other grounded items. The negative side should be the less shielded male connector.

Operation of a crimp plier is pretty basic and there are different sizes for the different wire gauge connectors.

NEVER attempt to make a crimp connection to a solid wire. It will not hold properly.

The reason Soldering is avoided as it makes stiff and fatigue susceptible areas that can break over time.

LABLE and color code each end of a wire run. It will save a lot of headaches now and later.
Make a schematic diagram and keep it readily available as well as updated.

For all but the highest amperage circuits the use of modern marine grade manually resetting circuit breakers are recommended over fuses.
The slight increase in cost over fuses will provide huge benefits. Circuit breakers are as, if not more, reliable than fuses. If tripped they can be reset without wandering around looking for a spare fuse of the right amp rating that you may or may not have available when you need it most. Barrel type fuse ratings are hard to read even under the best of circumstances. Blade type fuses are difficult to remove/replace without an appropriate tool. It is often difficult to visually see if either a barrel type or blade type fuse has actually blown.
Most all resetting circuit breakers have an obvious visual and tactile indicator to show it has popped so identifying the errant circuit is straight froward, even in the dark.

The exception is when dealing with high amperage circuits such as positive battery post current limiting applications. Given that most primary battery terminal locations are not readily accessible and space limited terminal fuses are a valid option from a cost and space perspective. One should have a current limiting device, fuse or circuit breaker within 7 inches of the battery terminal. Mounting it to the battery terminal meets that requirement. If space and access allows a properly rated resettable circuit breaker will often be a better and more reliable choice in that you won’t be looking for a spare fuse, nor will you be needing the time/tools/spare/access to remove/replace the blown fuse. It’s a choice one needs to make and provide for (as in having the appropriate replacement fuses on board along with any tools/knowledge required).

Hope this helps some.

Best Regards,
Over Easy 8) 8)

PS: When I redid the wiring system on Over Easy we went with an all indicating resettable circuit breakers approach. That way just about anyone, even in less than optimal conditions, can immediately identify and reset the affected circuit both now and in the future. We posted our electrical system in the Mods section.
OverEasy
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Re: Investing in paint for my ‘98X

Post by OverEasy »

Hi Herschel!

You look like you’re set for for armed combat with that trailer all kitted up and the that grinder/wire brush! :D :D
That garden chair is what I’d consider the perfect ‘tool’ accessory too!
(As I’d be utilizing it after all the bending and crawling around that cleaning up a trailer for repair and paint involves! :D )

That was a big job!

Best Regards
Over Easy 8) 8)
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Be Free
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Re: Investing in paint for my ‘98X

Post by Be Free »

ris wrote: Tue Dec 30, 2025 2:35 pm Hershel that paint job looks nice. We did a complete rewire on our boat and found a bucket full of wire that went no where. We were unable to rewire the running lights, the red, green and the rear white light. Never figured out where the wires ran except it is behind the interior liner somewhere. Those lights still work fine. We also added a few interior lights. LED one foot long strip lights in the back under the cockpit and a couple of lights over the table, along with numerous 12 volt plugs for fridge, phones ext.
For future documentation:

On the :macx: , the running lights run along the port side between the hull and the cabin liner. Most of the time it will be in the lip formed at the bottom of the cabin top. I never found it running anywhere higher than the bottom of the windows.

The bow light will come out of the liner in the v berth and you will find it tucked in very high around the bow where the deck meets the hull. It is not terribly difficult to get to if you need to replace it.

The stern light will be harder to get to. It is reasonably accessible tucked in very high in the aft berth between the cockpit and the inner liner. It gets trickier when it gets to the port side of the transom. It turns through the corner and then up through the cockpit coaming. The sharp turns and the flotation in that area make it the hardest spot to work on.
Bill
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Herschel
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Re: Investing in paint for my ‘98X

Post by Herschel »

Over Easy, that was an amazing tutorial. And what is a little scary---I understood about 90% of that. You have me curious about giving it a go. I am curious what gauge wiring you found in the "spaghetti?" And what you recommend for replacement if necessary? When I had my macerator wiring replaced a few years back, I was told that household extension cord wiring had been used by my PO to install it. It was replaced by the marine grade wiring you discussed. I'll digest this further. Thank you for taking such time and effort to go through this. Before I go down the electrical thread further, I do want to post the info for my talented and hard working marine tech who painted my topside and the hull bottom. He is Rob at RM Boatworks, 451 Marina Rd., Titusville, FL 32796. Phone 321-291-1002 and 321-362-2830. Titusville is on the ICW due east of Orlando. His shop for painting is in Rockledge, FL about 20 miles to the south. He had the boat about two months. I was very patient. I wanted a good job. He did that plus bought and installed a new tongue wheel on my trailer at no charge.
OverEasy
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Re: Investing in paint for my ‘98X

Post by OverEasy »

Hi Herschel!

8) Happy New Year! 8)
What a nice way to start it with a beautiful new paint job! :wink:
The new Bimini will only add sparkle to an already beautiful boat!

I’m glad you found the information useful. :)
Be Free did an excellent job of describing the original factory wire runs!
(I wish I had asked when doing our boat! :o :wink: Trying to chase back in the blind where/why things went was interesting to discover :D :D )

To keep things simple on our project I standardized the radio/bow/stern/cabin lights and the additional circuits added to the pedestal at 16 gauge. These are a all pretty low amperage draw circuits and that gauge was more than adequate given the wire runs aren’t long, that they are DC and the circuit breakers are set a 5 amp. For the engine starter/alternator wires I went with 6 gauge in tite-flex conduit from the Perko switch to a junction box on the starboard sidewall of the stern in the aft berth. That work out well for our situation in that at the time we were making provision for an engine change to our current Suzuki DF60AV and knew that we would be getting new high flex cables with the new engine. These cables get the most active dynamic flexing of any cables on the boat and our Suzuki Dealer was giving these new Suzuki cables to us as part of the installation. I used the tite-flex conduit as these cables run through the bilge and could be subject to bilge water.

Best Regards,
Over Easy 8) 8)
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Be Free
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Re: Investing in paint for my ‘98X

Post by Be Free »

Kudos for using conduit in the bilge. That's one that a lot of folks skip.

I'll agree that 16 AWG is a good choice for anything that the factory installed. ABYC (last I checked) allowed you to go down to 18 AWG but that's marginal even for our boats as they were originally wired. It was not so much that the wires could not carry the load, it was that there was so much voltage drop on the longer runs. It was (barely) within acceptable ranges when it was new but there was not much room for degradation over the years.

The first wire I replaced was feeding the anchor light on top of the mast (not to be confused with the masthead light on the front of the mast :wink: ). Using a larger gauge wire gave me a measurable decrease in current and allowed me to keep my anchor light on all night without killing my original house/start bank.

Something to keep in mind for long runs or heavier, critical loads.
Bill
2001 26X Simple Interest
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OverEasy
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Re: Investing in paint for my ‘98X

Post by OverEasy »

Hi Be Free!

Yes, that is a good point!
The bigger the wire (lower gauge number which may be counter intuitive for some) the lower the line run resistance.
With the short runs I was dealing with it wouldn’t make much difference but I can very well see your point with a mast head run and fully agree that a bigger gauge really can make a difference. I can also see the getting a higher strand count for that application would also be worthwhile given that the wires inside the mast would be much more dynamic than the ‘relatively’ static conditions of the cabin areas.

In full disclosure, As we’ve been operating in motor cruiser mode (mastless) I haven’t redone the in mast wires or deck fitting as yet. It’s on my future TBD list. (Right after the tabernacle and hard Dodger which are still to be done….)

Adding a strain relief of some sort would also be a good idea to address the long vertical hanging weight of the wiring inside of a mast.
I admit I haven’t really gotten into that aspect as yet. I was considering going with a high strand count heavier gauge overjacketed twisted wire pair for the mast lighting wires and a nitrile cushioned cable clamp at the top where there is some limited access.

At the mast base I was also looking at something more protected than the existing loose wire that currently exists. It looked like there had been some sort of scuffing abuse of the wires over the years. I’ve seen some high flex stainless and UV resistant vinyl armored sheath that looks like it would work on some other boats.

Same goes for the existing 2-conductor deck electrical connection. When we get to that aspect on the TBD list I think I’d rather replace it with a larger more robust connector with a higher number of conductors. As well as a mast head and anchor lights we’d be adding a pair of downward facing deck lights to the yards (cross arms) and possibly a pair of area lights angled further out. That would be an eight conductor weather tight connector with a protective collar/cap. That all gonna be further on down the road though.. I’m still working on getting to the other items on the To-Do-List :D :D

Any experience, suggestions or other approaches are appreciated.
There’s always multiple good ideas to be considered.

Best Regards,
Over Easy 8) 8)
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Be Free
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Re: Investing in paint for my ‘98X

Post by Be Free »

You can design your cabling in the mast to use a shared ground wire. That would cut down on the number of pins you will need in your deck connector but you will need to keep track of the polarity on your circuits.

Fair warning: there is no consistency in the factory wiring. The lamp cord has a smooth jacket on one wire and a ribbed jacket on the other. There was no attempt to be consistent as to which was positive and which was negative. Incandescent bulbs don't care and neither did the installers.
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Russ
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Re: Investing in paint for my ‘98X

Post by Russ »

Be Free wrote: Fri Jan 02, 2026 7:13 pm You can design your cabling in the mast to use a shared ground wire. That would cut down on the number of pins you will need in your deck connector but you will need to keep track of the polarity on your circuits.

Fair warning: there is no consistency in the factory wiring. The lamp cord has a smooth jacket on one wire and a ribbed jacket on the other. There was no attempt to be consistent as to which was positive and which was negative. Incandescent bulbs don't care and neither did the installers.
I found when replacing cabin lights with LEDs many fixtures were reversed polarity. The incandescent bulbs don't care.
LEDs typically are polarity dependent and won't light if reversed. WHICH I found useful in using the original 2 wire deck fitting and wires for the mast lights. Steaming and Anchor lights are wired using the same pair. I reversed one fixture so I can alternate by reversing polarity.

Reversing polarity is simple by using a DPDT switch back by the main panel.
--Russ
OverEasy
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Re: Investing in paint for my ‘98X

Post by OverEasy »

Hi Russ and Be Free!

Yeah, polarity can be a two edged issue. Good you brought this up!
The center tap of a 12 VDC screw in bulb is supposed to be the positive and the threaded portion should be the negative side.
(The fuse and switch should also be on the positive side ahead of any load… found it done wrong way round several times :o :( :D )

Excellent suggestion! I’d forgotten about that trick! In some industrial equipment situations with incandescent lights in DC systems I’ve seen (and subsequently copied … a good idea is a good idea :wink: ) the use of three position Double Pole Double Throw (DPDT) switches wired up with diodes to achieve what Russ described with his LED lights to have a common wires going to two different lamps. It’s a great way to save on multiple wire runs in situations like the mast!

Best Regards,
Over Easy 8) 8)
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Herschel
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Re: Investing in paint for my ‘98X

Post by Herschel »

Be Free wrote: Thu Jan 01, 2026 4:00 pm Kudos for using conduit in the bilge. That's one that a lot of folks skip.
I'll agree that 16 AWG is a good choice for anything that the factory installed. ABYC (last I checked) allowed you to go down to 18 AWG but that's marginal even for our boats as they were originally wired. It was not so much that the wires could not carry the load, it was that there was so much voltage drop on the longer runs. It was (barely) within acceptable ranges when it was new but there was not much room for degradation over the years. The first wire I replaced was feeding the anchor light on top of the mast (not to be confused with the masthead light on the front of the mast :wink: ). Using a larger gauge wire gave me a measurable decrease in current and allowed me to keep my anchor light on all night without killing my original house/start bank. Something to keep in mind for long runs or heavier, critical loads.
My masthead anchor light is not coming on. It is a newer LED fixture I had installed about 5 years ago. I hope to get that checked out this month. I have to borrow a larger ladder to gain access to the top of the mast. In the meantime, I finished cleaning down the bulkheads in the cabin today. Crawling into the under cockpit "berth" facing astern is more like spelunking than I care to do very often especially on the starboard side. 15 minutes to wipe down the sides and I was ready to get out of there. I cannot imagine trying to sleep on that side of the lower berth. :| I did inspect the fittings on the tubing that drains the transom "pond" out the stern. All FIVE connections sound. Probably good to check every time we do some major maintenance (what we would call a yard period in the Navy). Scenes from my "man cave." 8)

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Be Free
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Re: Investing in paint for my ‘98X

Post by Be Free »

If you have a multi-meter with a diode function you can do the initial check on the wiring to the anchor light without a ladder. If you don't have a diode function you can still test half of the circuit.

Unfortunately, wiping down the inside of the cabin is a regular maintenance item in our humid climate. I've found that if I use disinfectant (chlorine bleach) wipes or spray that it will work for about a year. Without the disinfectant it may need to be done again if the the boat sits for a while. At least it wipes off easily.
Bill
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