Mast Down, Sheaves Out, and Wiring Nightmares

Not every refit weekend brings good news. I set out planning to fit the new halyards and finally get the running rigging sorted, but instead I ended up pulling the mast off the boat.

The sheaves at the base of the mast, which I thought just needed replacing, turned out to be completely seized. Solid. No amount of WD-40 or gentle persuasion was going to get them turning, so the mast had to come down. It’s now resting on top of the boat, which makes getting around a bit awkward, but it’s only temporary. Once I had the mast down and could properly measure the parts, I found out that nobody makes sheaves in this exact size anymore. Of course. So I broke out the calipers, fired up the 3D printer, and made my own set. Not quite the simple job I had in mind for the weekend, but at least I know they’ll fit perfectly.



With the mast down, I took the opportunity to tackle a few other jobs. I replaced a waterlogged navigation light and then turned my attention to the wiring. And wow. I knew the electrical system was bad, but I didn’t realise quite how bad until I started tracing wires. The previous owner had used 1.5mm domestic house wiring (brown and blue cables like you’d find in a wall socket) for everything. That might fly in a kitchen, but on a 12V DC system it’s completely wrong. There’s no live and neutral here! Everything is getting replaced with correctly sized, marine-grade red and black wire.



I’ve now ripped out every inch of the old wiring and started designing a new control panel from scratch. It’s a lot of work, but it feels good to be building a system I can actually trust. And let’s be honest: if I didn’t fix this now, it would probably have come back to haunt me at sea.

For now, the boat looks a bit like a science experiment with wires hanging everywhere and the mast lying across the deck, but this is progress. Sometimes you have to go backwards to go forwards, and I’d rather discover all this on the hardstanding than halfway down the Thames.

Sidebar: Why House Wiring and Boats Don’t Mix

Domestic wiring is designed for fixed installations at 230V AC, where a blue “neutral” and brown “live” make sense. On a 12V DC boat system, polarity matters, vibration is constant, and moisture is inevitable. Household cables aren’t tinned to resist corrosion, the insulation isn’t rated for marine conditions, and a single bad connection can create resistance that eats away at both efficiency and safety.

Marine-grade wire uses tinned copper strands, colour codes (red for positive, black for negative), and high-quality insulation designed for a damp, salty environment. Switching to proper wiring means fewer voltage drops, easier troubleshooting, and a much lower chance of your boat turning into a floating bonfire.


Next up: a custom-built electrical control panel, brand-new halyards, and (hopefully) getting the mast back where it belongs. 

Comments

Post a Comment

Popular posts from this blog

I Bought a 1979 Achilles 24 - What Could Possibly Go Wrong?

Image
I bought a boat. Specifically, a 1979 Achilles 24 - or something very close to it. I say “1979” with the same confidence you might say, “This milk smells fine.” It’s not confirmed, but based on the sail number and a few key design features, it’s a solid guess. Close enough for now. She’s red, fiberglass, and let’s be honest, rough. But she’s mine. This blog is where I’ll be documenting the resurrection of this little cruiser, from barnacle-bedraggled beginnings to blue-water dreams (or at least weekend sailing without sinking). Think of this as part restoration log, part therapy, and part warning for anyone else thinking, “How hard could it be?” The Boat & The Buy The Achilles 24 has a bit of a cult following among small cruiser fans, and for good reason. Designed by Oliver Lee and built by Butler Mouldings in the UK, it’s a 24-foot, fin-keeled fibreglass sloop that punches well above its weight in terms of sailing ability and rugged charm. According to the Achilles Owners Associ...
Read more

Starting the Restoration: Making a 1979 Achilles 24 Seaworthy Again

Image
This past weekend was meant to be the first big push into restoring the Achilles 24. I had a packed to-do list, tools loaded, and sunscreen ready. But late Friday night, a huge fire broke out at an industrial estate just down the road from Erith Yacht Club. It took 150 firefighters and 25 engines to bring it under control, and the surrounding area was closed off on Saturday while crews dealt with lingering hotspots and smoke. The fire service laid 2 kilometers of hose and pumped water from the Thames One of the key things I’d planned for Saturday was tractor training at the club. It might not sound glamorous, but it’s a big deal. Members who are trained to operate the club’s tractors can move boats around the yard and down the slipway, including getting my own yacht from storage to the work sheds where I can hook up to power and water. It’s also a way to give back, since I’ll be able to help other members launch and recover their boats during the season. Unfortunately, the closure mean...
Read more

Tractor Training, Sealing Leaks, and Stuck Winches

Image
  Another solid weekend of progress on the Achilles 24. This time, it actually started on Friday. The day started with the removal of the corroded remains of an ancient brass seacock - the valve that allows the onboard sink to drain overboard and can be closed to prevent seawater ingress. It had been left open, and fell apart in my hands when I tried to close it. Thankfully, the bronze skin fitting is still in good shape, so I only had to order a new valve. I’ve opted to use a composite valve from Trudesign out of New Zealand. The valves are very highly rated and being plastic, won’t corrode. I also ordered some stainless steel jubilee clips to reconnect the sink drain. After last week’s disruption thanks to the industrial estate fire, I was finally able to complete tractor training at the club. I’ve been looking forward to this for a while. Not just so I can move my own boat around, but also so I can help out with launches and recoveries. Big thanks again to Alan Thomas for taking...
Read more