2004 Montauk 170 Combined Sidelight Lamp Repair

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Author Topic:   2004 Montauk 170 Combined Sidelight Lamp Repair

Marsh posted 06-24-2009 01:18 PM ET (US)
The plastic red and green lens of the combined sidelight lamp [used on a c.2004 Boston Whaler 170 MONTUAK boat] is secured to its base by three small plastic tabs that hook into the base as the lens is rotated into place. In the past two years, I have had to replace this lens twice after one or more of the tabs broke. The reason for the replacement is that without the tabs, the lens does not secure itself tightly enough to the base to maintain a ground contact, resulting in failure of the lamp.
Has anyone found a better remedy? I am trying to buy my latest replacement lens thru Sue at TCM, but wonder if there is a better source, or a more permanent solution?
Quite frankly, although I'm not an engineer, the entire design seems faulty to me, not nearly robust or durable enough for the long term.
Marsh

wbullwin posted 06-24-2009 02:33 PM ET (US)
I'm not an electrical engineer but a plastic lens should have nothing to do with getting a good ground. I would look farther into the light to see if something else is loose or corroded.
Marsh posted 06-24-2009 02:44 PM ET (US)
The ground is established when a thin wire, embedded into the lens, comes into contact with the base as the lens is tightened. When the plastic tabs break off (as they will do over time), the lens becomes loose on its base, and the embedded wire loses contact.
Marsh
Marsh posted 06-24-2009 04:38 PM ET (US)
No worries. Sue at Twin cities Marine is sending me a new lens for $13.95. That's pretty cheap.
Per Sue, Whaler has already redesigned the bow light twice due to its shortcomings.
Marsh
wbullwin posted 06-25-2009 09:49 AM ET (US)
Obviously, you can see I never took my light apart and since I never run at nights, I don't even know if it works now. I know it did when I got the boat used 3 years ago and I will check. That design is the craziest thing I ever heard of. Why would they ever embed a wire in a plastic lens? Maybe you could add a wire and bypass the lens? Whatever! At least you are up and running.
FYI, Mine is a 2003
Marsh posted 06-25-2009 04:19 PM ET (US)
A word of caution in case you take your combined sidelight lamp apart: Once the metal shroud is removed, press down firmly on the plastic lens, and while pressing down, rotate the lens CCW to release it from the base. Failure to press down will break the plastic tabs for sure.
Marsh
wbullwin posted 06-26-2009 08:28 AM ET (US)
Marsh--Thanks for the heads up. I probably would have just tried to pull it out and then I would be at the dealer like you have been. Thanks.

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Author	Topic: 2004 Montauk 170 Combined Sidelight Lamp Repair
Marsh	posted 06-24-2009 01:18 PM ET (US) The plastic red and green lens of the combined sidelight lamp [used on a c.2004 Boston Whaler 170 MONTUAK boat] is secured to its base by three small plastic tabs that hook into the base as the lens is rotated into place. In the past two years, I have had to replace this lens twice after one or more of the tabs broke. The reason for the replacement is that without the tabs, the lens does not secure itself tightly enough to the base to maintain a ground contact, resulting in failure of the lamp. Has anyone found a better remedy? I am trying to buy my latest replacement lens thru Sue at TCM, but wonder if there is a better source, or a more permanent solution? Quite frankly, although I'm not an engineer, the entire design seems faulty to me, not nearly robust or durable enough for the long term. Marsh
wbullwin	posted 06-24-2009 02:33 PM ET (US) I'm not an electrical engineer but a plastic lens should have nothing to do with getting a good ground. I would look farther into the light to see if something else is loose or corroded.
Marsh	posted 06-24-2009 02:44 PM ET (US) The ground is established when a thin wire, embedded into the lens, comes into contact with the base as the lens is tightened. When the plastic tabs break off (as they will do over time), the lens becomes loose on its base, and the embedded wire loses contact. Marsh
Marsh	posted 06-24-2009 04:38 PM ET (US) No worries. Sue at Twin cities Marine is sending me a new lens for $13.95. That's pretty cheap. Per Sue, Whaler has already redesigned the bow light twice due to its shortcomings. Marsh
wbullwin	posted 06-25-2009 09:49 AM ET (US) Obviously, you can see I never took my light apart and since I never run at nights, I don't even know if it works now. I know it did when I got the boat used 3 years ago and I will check. That design is the craziest thing I ever heard of. Why would they ever embed a wire in a plastic lens? Maybe you could add a wire and bypass the lens? Whatever! At least you are up and running. FYI, Mine is a 2003
Marsh	posted 06-25-2009 04:19 PM ET (US) A word of caution in case you take your combined sidelight lamp apart: Once the metal shroud is removed, press down firmly on the plastic lens, and while pressing down, rotate the lens CCW to release it from the base. Failure to press down will break the plastic tabs for sure. Marsh
wbullwin	posted 06-26-2009 08:28 AM ET (US) Marsh--Thanks for the heads up. I probably would have just tried to pull it out and then I would be at the dealer like you have been. Thanks.