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Old 13-02-2022, 00:23   #1
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Bulkhead cable pass-through

Hi All

I have a 6mm aluminium bulkhead between the forward cabin and anchor locker through which I plan to run a bunch of cables serving the windlass. There will be three big (AWG1) power cables, a cable for the chain counter and another for the deck foot switch.

There are many cable pass-through's/glands on the market but none that I have found which could accommodate these 5 cables in one fitting. There are some I've found that would fit one of the AWG1 cables plus a smaller cable, but no more than that. So if I go with this option, I'd need a minimum of 3 penetrations/glands through the bulkhead.

This might be my best option, but I thought I'd run it by you guys/gals to see if there's other ways. Just to put it out there, I thought about cutting a larger hole to accommodate all cables but I'm unsure how I'd protect the cables and properly seal the penetration.

Any ideas?

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Old 13-02-2022, 00:42   #2
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Re: Bulkhead cable pass-through

I would cut and deburr 1 larger hole (50mm?), then split and strip some insulation off of a suitable size cable, and then run this around the cut edge gluing it securely into place.

Electricians have been using this method for ever.
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Old 13-02-2022, 01:00   #3
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Re: Bulkhead cable pass-through

Blue Sea Cable Clam -- Drill a hole for each cable, add a bit of 5200, and assemble. Use multiple clams as needed.



https://www.bluesea.com/products/1003/CableClam_1.40in
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Old 13-02-2022, 01:52   #4
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Re: Bulkhead cable pass-through

Quote:
Originally Posted by markcouz View Post
I would cut and deburr 1 larger hole (50mm?), then split and strip some insulation off of a suitable size cable, and then run this around the cut edge gluing it securely into place.

Electricians have been using this method for ever.
Thanks for that. But how would I seal the penetration? Itís only 6mm thick.
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Old 13-02-2022, 01:53   #5
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Re: Bulkhead cable pass-through

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Originally Posted by Viking Sailor View Post
Blue Sea Cable Clam -- Drill a hole for each cable, add a bit of 5200, and assemble. Use multiple clams as needed.



https://www.bluesea.com/products/1003/CableClam_1.40in
Thatís definitely an option but Iíd hoped to minimise the number of penetrations.
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Old 13-02-2022, 02:28   #6
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Re: Bulkhead cable pass-through

Are you wanting it to be watertight or do you just want to protect the cables?

I doubt it will ever be totally watertight if you pass multiple cables through one gland.
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Old 13-02-2022, 03:00   #7
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Re: Bulkhead cable pass-through

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Originally Posted by aqfishing View Post
Are you wanting it to be watertight or do you just want to protect the cables?

I doubt it will ever be totally watertight if you pass multiple cables through one gland.
Good question! Ideally both but cable protection is essential especially given the high amp loaded cables rubbing against aluminium plate. The previous owner had installed a junction box on the external face of the bulkhead, using cable glands through that and then siliconing everything inside. It seemed a bit Heath Robinson but perhaps it was a good solution. I just need to check what alternatives there might be.
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Old 13-02-2022, 04:21   #8
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Re: Bulkhead cable pass-through

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Originally Posted by Wideocean7 View Post
Thanks for that. But how would I seal the penetration? Itís only 6mm thick.
If drilled high enough through the bulkhead probably unnecessary to seal, just inject some PU foam for basic seal and cut away excess to neaten up afterwards.
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Old 13-02-2022, 05:05   #9
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Re: Bulkhead cable pass-through

My immediate thought was a thru hull fitting.

BUT I know there are fittings on the market designed for exactly what you want to do. I just did a google and came up with this:


https://www.google.com/search?q=pvc+...mgrc=Q2-8calg5JOz7M
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Old 13-02-2022, 23:35   #10
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Re: Bulkhead cable pass-through

Since you have an aluminium bulkhead, how about a commercial marine solution? Weld an aluminium Roxtec frame in, and then you have a rated fully sealable transit that you can even run additional cables through at a later time.
Both round or rectangular frame shapes are available that you can select from. Correctly selected, they will accommodate any sizes and combinations of cables. Example of an Aluminium rectangular transit that may fit your application in the image attached.

See https://www.roxtec.com/au/products

I have no commercial interest in this product, but have specified and installed thousands of these over my professional career, and have no reported failures when installed as per OEM instructions.
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Old 15-02-2022, 23:47   #11
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Re: Bulkhead cable pass-through

If you hold all the cables in a bundle that you want to go thru one hole, how big of a hole do you need? (Allowing for a couple extra duplex wires).
A #1 cable isn't that big, other wires smaller.
Anyway, fit a commensurate sized piece of heavy wall hose, like stuffing box hose or heavy exhaust hose thru the drilled/cut hole in the bulkhead, careful work will obtain a hole that you have to kind of "twist" the hose thru.
Feed thru the wires/cables and squirt the hose full of foam.
You only need a few inches of hose.
Alternately: Are there means to support/fasten the hose on either side of the bulkhead?
If so, job may be made easier.
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