Rewiring a 2003 160 Dauntless

Electrical and electronic topics for small boats
Todd
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Rewiring a 2003 160 Dauntless

Postby Todd » Mon Mar 12, 2018 10:10 am

Hello. Now that we have Spring on the horizon here in Michigan, I am planning a few projects on my 160 Dauntless. One of those projects may be updating and replacing (or at least organizing) some of the original wiring on the boat. When I bought the boat last year, the surveyor said the wiring was a bit of a "mess." My evaluation was that, although everything works, it does look a little like an explosion in a spaghetti factory in the center console. I've seen many pictures of correctly wired boats on this site and realize mine has a long way to go. The boat has two batteries, stereo (which I may replace), VHF, bilge pump, and the usual complement of gauges.

Can a novice like me update this on my own?

Or, would I need a professional?

Any and all advice would be helpful and any suggestions on resources appreciated. Thanks--Todd

jimh
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Re: Rewiring a 2003 160 Dauntless

Postby jimh » Mon Mar 12, 2018 10:59 am

TODD--My expectation for a 2003 Boston Whaler boat is the original electrical wiring at the helm would have been installed in a professional manner. Over the 15-years the boat has been in service since leaving the factory, owner-added or dealer-added electrical wiring may have been accomplished with less attention to appearance than the factory rigging.

For some advice, please see

DC Power Distribution Updating
http://continuouswave.com/forum/viewtopic.php?f=9&t=3233

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Phil T
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Re: Rewiring a 2003 160 Dauntless

Postby Phil T » Mon Mar 12, 2018 11:35 am

At some point, maybe 2002 to 2003, all Boston Whaler boats had their engines and [engine] wiring installed at the factory. Prior to this, the selling dealer did the engine install and associated wiring.

The factory wiring was standardized, followed code, and was somewhat sensical.

I have done two complete re-wire projects: a 1987 Montauk 17 and a 1991 Outrage 17. Both boats were a disaster. The Outrage 17 was the worse since it was re-powered prior to purchase and the installers cut and hacked the existing wiring. Sharing this so that if you have spaghetti, don't feel bad.

First thing I do is draw a rough diagram of what the wiring is doing. Show colors. Once I understand what needs to be there, you can decide how to improve it, in addition to cleaning it up. You can make a list of all the wire you need by color and gauge, list of terminal rings, connectors, and etc.

Figure out where you want the wiring to go and how it will be protected (wire loom) and attached in the console.
Member since 2003
1992 Outrage 17, 1992 Evinrude 115

Todd
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Re: Rewiring a 2003 160 Dauntless

Postby Todd » Mon Mar 12, 2018 1:48 pm

Thank you Phil for taking so much of your valuable time to assist me. I am printing your guidance to help me as I work through the project. I'll take my time and document, document, document. One thing I can do that you identify is taking pictures of the work that will help me as well, your picture shows me what the finished product should look like. I bought this boat hoping I could do much of the work on it rather than sending it to the marina and it really helps to have folks with expertise to bounce these topics off. Thanks again. Todd

jimh
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Re: Rewiring a 2003 160 Dauntless

Postby jimh » Tue Mar 13, 2018 9:07 am

Todd wrote:Thank you Phil....your picture shows me what the finished product should look like.


Phil is a handsome fellow: Image
But I am not sure his picture is going to help you do the wiring.

:-)

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Phil T
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Re: Rewiring a 2003 160 Dauntless

Postby Phil T » Tue Mar 13, 2018 11:29 am

Here are two photos to show how well re-wiring can turn out. The first is after running all the new wiring, adding Bus Bar, battery switch, etc. The second is after it is all bundled up. I wrapped everything in loom or bilge hose since it is in a console that gets items thrown in. Would not want a wire to get loose.

Rough:

IMG_0092.jpg
IMG_0092.jpg (43.64 KiB) Viewed 468 times


Cleaned up and secured:

IMG_0107.jpg
IMG_0107.jpg (35 KiB) Viewed 468 times
Member since 2003
1992 Outrage 17, 1992 Evinrude 115

jimh
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Location: Michigan, Lower Peninsula
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Re: Rewiring a 2003 160 Dauntless

Postby jimh » Tue Mar 13, 2018 3:23 pm

PHIL--from the image you provide it appears that you are using some sort of split hose as a flexible conduit for electrical cables. I don't endorse that use; the exit of wiring from the conduit will be via the split portion, which would have a risk for abrasion of the wire insulation against the hose material.

Todd
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Re: Rewiring a 2003 160 Dauntless

Postby Todd » Thu Mar 15, 2018 11:37 am

I've printed all the excellent direction from you both and will begin the project as soon as it's warm enough in my garage to work. All great suggestions and thoughts. I do think the best approach is to pay for you two to visit me for a few days (all expenses paid of course) and supervise the work! Thank you both very much. Todd