Electric Winch on Catalina 36-2

[Roy M]

I'm installing a Lewmar 40 electric winch on a customer's Catalina 36-2. Routing of the power cables, 2/0 pos and neg, is turning out to be a special challenge. At first, it appeared possible to run them through the bilge from the overhead of the aft berth cabin. That isn't working out. My remaining option is to surface mount them at the margin of the cabintop to outboard cabinside wall, then use something cosmetic to cover them. Has anyone opened up the soles under the teak and holly ply? There appears to be some space there, with drainage sub-plywood, into a bilge space. I'll send pic of the installation when it's done. The winch is to raise the halyard for the owner's wife who has some strength issues and it's located to the starboard side of the companionway hatch.

[Stu Jackson]

You might be get some feedback from the C36 guys at Catalina 36/375 International Association | "It's always nice when there is a support network for used boat buyers and Catalina 36 has one of the best" (Boat US), join their forum.

[Roy M]

I figured it out, though not without a few anxious moments as I drilled out some large holes through blind fiberglass panels: the power cables pass from the distribution area behind the nav table, through the bulkhead to the hanging locker of the aft cabin, down to the bottom of the cabinet, through the void beneath the drawers, through a thin fiberglass wall into the starboard side of the bunk locker, then into the (hollow) transverse fiberglass wall supporting the bunk's forward edge (forward of the water tank), then up through the top, at the bulkhead that is outboard of the companionway. It's actually shorter, by several costly feet of 2/0 cable, than the original route I had been exploring. Today I pull cable, install new battery selector switches, a starting battery and other goodies. Details and photos to follow, as soon as I can get some stuff cleaned up. Lewmar sent me the shaft extension needed for installing the winch on Catalina boats, and I sent the drive motor to the canvasmaker to have an Ensolite/vinyl cover made to protect noggins from damage.

Thanks for the info on the Catalina forum. I'll send some info to them when this adventure is finished.

[James S]

Are you going to be able to fasten/support it and protect it from chafe through all those places?
Flexible conduit?

[Roy M]

Yup. Sometimes I just use conventional throughhull fittings, but this time, due to the need for additional diameter, I am using 1 1/2" plastic pipe couplings, glued in with 5200. They provide great longitudinal support, eased edges, and the hex head at the middle forms an ideal stop to fitting in a 2 inch hole. The balance of the run is supported via quickties and cable straps. You'll see them in the photos when I'm finished with the installation. I try to avoid conduit wherever possible for several reasons: the 2/0 cable is pretty massive already, it's well shielded by heavy insulation, and, since it's a royal pain to pull the anaconda through its length, trying to do so in conduit would be worse. I know this because, in some situations, such as transiting an engine room, I've had no option. Also, it allows me to later "piggyback" additional wiring with ease to remote locations using the holes and support previously provided.

[James S]

Cool....looking forward to the photos Roy.

[Roy M]

Okay, the project is now finished. Here are some pics:

First, removal of the old winch base, drilling the pilot hole for positioning of the drive motor, and drilling the shaft hole. While doing this part I discovered a large void between the overhead and the balsa core deck, requiring spray foam filler.

[Roy M]

Sorry about the orientation of the pics. I'm doing this post from my phone and haven't got edit control down yet.

Next step was to rebuild the winch base and restore the deck nonskid using West System 407 and 410. I used a straight edge and file to score the diamond pattern, then primer and a color matched Sterling LPU to cover.

Oops! My attachments are crashing. I'll continue later when I can use my laptop.