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Author Topic:   Rewiring a Montauk
bboeri posted 07-06-2007 04:09 PM ET (US)   Profile for bboeri   Send Email to bboeri  
Hello All1 I have a 1988 Montauk running a 1988 Johnson 88 SPL. I think it is time for me to rewire the boat as I am constantly getting shocked when the boat is wet. I would also like to move the battery into the console and add a battery switch and charger. Does anyone have a wiring diagram of how to do this all? I know that there is one on the reference site for a 2 motor set up, but I am not enough of an electrician to do it for one without instruction. I would appreciate any help. Thanks in advance.

Bob

Casco Bay Outrage posted 07-06-2007 09:30 PM ET (US)     Profile for Casco Bay Outrage  Send Email to Casco Bay Outrage     
Hey Bob -

I did a rewire project on my 1987 Montauk and on my 1991 Outrage 17.

I did a wiring diagram for both but don't have them handy. Also, not sure it would help you since you may have different electronics, gauges etc.

Can you answer:

Brand of engine/control
What electronics do you have?
Brand and kind of gauges?
What switches do you have (and what do they do)now and what do you want in the new plan?
Do you want a standard bus bar (rigged by BW) or one of those neat new kind with fuses/cover?

Before doing ANYTHING, draw a detailed diagram of all the wires, where they go, colors etc.

Figure out what changes you want to make. I decided to move gauges around and also install a bus bar. It is important to know this before you start.

Cut the floor in the console so the battery sits on the deck.

Dry fit the battery selector and charger. Once there, see how the ergonomics work for the space inside the console.

When I disassembled the wiring, I marked both ends of a wire with tape and wrote on it what it came from and where it went. (This saved me a big headache several times when I got totally confused).

I removed all the old connectors and installed new ones.

I found several highways of wires:

From the tunnel to top of console (e.g gps, vhf antenna)
Tunnel to throttle
Tunnel to bus bar

I established the routes first, then started running the wires. For small groups of wire I used wire loom. For larger groups I used bilge hose.

I used loose zips to keep everything together. After all testing to make sure it was all working, I covered in loom and then did the final zip ties over the loom.

I took Jim H's advice included extra length for the panels so I can pull the panel out.

For the battery, use 2 gauge tinned wire up to the console and the selector.

Here is a before shot of the inside of the Outrage console http://s83.photobucket.com/albums/j291/CascoBayOutrage/ Outrage%20Rewire%20project/?action=view¤t=P7260163.jpg

Here is an after: http://s83.photobucket.com/albums/j291/CascoBayOutrage/ Outrage%20Rewire%20project/?action=view¤t=P8210008.jpg

Hope this helps.

Phil

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