Deck stepped mast leak.

[JWBenson]

I have a deck stepped mast. The mast wiring comes through the deck via a hole that is on the mast step and inside the mast. The problem with this is that any water that gets inside the mast comes through that hole. I have had to do major repairs on my compression post and want to permanently fix this problem. Iím thinking about leading the wires out of the mast about six inches above the deck and sealing the existing hole. I would then run the wires through the deck outside of the mast, inside a PVC or ? conduit. Questions:

ï I donít like the idea of drilling holes in my mast. How big of a hole is OK?
ï What type of conduit should I use?
ï Is there a good way to seal the new hole in the deck?
ï Is a drain hole needed at the bottom of the mast, how big?
ï Any other tips?
ï Is there a better solution?

[SV Papillon]

One way that it is done and seems to make good sense. Is to put a seperate fitting along side your mast step. You may be able to buy one or make your own. It is a piece of pipe in the shape of a inverted "J" with a flange that can be bedded and screwed to the deck. Two 90 deg SS tube fittings about 1" on about 3" of pipe and a flange. Your wires exit the mast via a fair hole then do a loop into the pipe and through the deck.

Jake

[Matthew Sebring]

What type of deck step do you have? It may be possible to weld a small stand up tube over the hole in the step. It needn't be tall, only an inch or so. This will serve as a collar to prevent all water from just draining in to the cabin.

[Brion Toss]

Hello,
You can put a standup tube ó preferably with a curved neck, to discourage water intrusion ó either inside or outside the mast. The former will be easier for you, as you won't need to drill a hole in the deck (though you will need to pick the mast). The latter allows for ready access to the wiring, for inspection, maintenance, and upgrades, though it can be a trip hazard. And I've know of some boats that had a stray line rip the wires out. Oh, and the external version is much easier to step, as you deal with the wires after the mast is in; just yesterday we were fussing at stuffing wires down a little-bitty hole in the mast step, with the Mast of Damocles hanging uncomfortably close to our hands.
My inclination in your case, since you already have a hole, with wiring routed, is to add a generously large internal gooseneck, with messenger rove to pull the wiring in from below, and cut an access port in the mast wall, near deck level. You'll need to fabricate a hatch that screws on to the mast, and this can be done from a bit of mast of the same section. Be sure to drill and tap for machine screws. A hole at this level is not much of a concern even if left open, but a properly covered hole should actually be stronger than the mast.
Fair leads,
Brion Toss