Re: Starting from scratch, NEW everything electrical.
Cal, I built my boat and therefore did a complete wiring job on it. (Two batteries, two bilge pumps, two fuel tanks, nav and cabin lights, horn, radio, GPS, etc.) Here are a couple of suggestions.
- Use high quality marine wire. Marine wire is usually tinned, which means it is not going to suffer the same type of corrosion you will see with plain copper wire. There really is a difference. Also, the jacket is usually more resistant to attack by certain liquids.
- Do not under size the wires. It is better to go
slightly oversized on the wire size. Ground wires and battery cables, however, are different. I definitely went oversize on those.
- Use the proper size ring terminal. Many people use fork terminals, but I prefer ring terminals even though they are more trouble to install. Please note that every crimp-on terminal has two sizes associated with it - the first is size of the wire, and the second is the size of the lug (screw) that it is connecting to. Always select the correct size for both. Use a good crimping tool, practice your crimping skills and make each one as close to perfect as you can.
- Route the wires in a well organized manner. Use ty-wraps (zip ties) to keep in neat bundles, and secure to the boat every 6 to 12 inches with cable clamps. There are nylon ones available, or the really nice stainless steel ones with the black rubber insulation/cushion on them. The SST ones are very rugged, seldom break and last many years.
- For unprotected areas where wires might get bumped, chaffed or snagged, use sprial wrap on the outside of the bundle. Use the high quality UV-resistant black stuff and not the thin, cheap, clear stuff. (I realize that putting this stuff on can be a hassle, but look on the bright side - you get to work on your boat!) Follow up with the use of cable clamps as described above.
- Use Dielectric Grease. I have found this to be
extremely effective in salt water. Specifically, I put a little dielectric grease on the end of every wire before I put it in a crimp terminal. Also, after crimping, I put a little dielectric grease on every ring terminal and lug (screw) before I attach it. Follow by tightening securely. I follow this same technique when making connections on battery cables. Grease first, then make the connection. It can be a little messy, but you can clean up when its all over. I am definitely of the opinion that you will have more years of reliable service and significantly fewer problems if you use dielectric grease on a connection
before you assemble it rather than smearing it on a connection after you have already made it. Use your good judgement when applying dielectric grease. Big globs of the stuff will attract dirt and cause leakage paths, but just the right amount will give you years of reliable service.
By following the few suggestions that I have made above, I'm sure that you can at least double - if not triple - the cost of the wiring job you have planned.
Nevertheless, a wiring problem when you're out on the water is a complete hassel, not easily fixed, and can even be a show stopper. Get it right when you're on the shore and you won't have to worry about it when you're out on the water. Best of luck with your project - Woodnaut
