64 Photos - Mar 4, 2014
Photo: Electrical Panel in Pilgrim when purchasedPhoto: taking apart the exisiting electrical systemPhoto: bilge access is limited on the Morgan 382Photo: dubious wirng in bilgePhoto: Factory equipment from Pilgrim's shore power wiringPhoto: two green batteries are house bank and blue battery is starterPhoto: damage done by past battery acid spill.  Note old wood shelf pieces in battery box up and left.Photo: looking aft at new quarterberth lockers.  The engine raw water intake & strainer are located aft midship locker.  The starter battery, battery selector switch,  bilge pump switches, & other electrical wiring are located in the forward mid ship locker.The two outboard lockers are for storage.Photo: Pattern for  Battery & Bilge Pump Management Panel  tapped into postion over site of original M382 battery selector switch. I traced the template using a marker then cut out the area using a jig saw.Photo: Cut out complete.Starter battery with temporary bilge pump wiring in background.  Next step...seal the edge of plywood cabinetry with a couple coats of epoxy.Photo: New Battery & Bilge Pump Management Panel installed on PilgrimPhoto: New Battery & Bilge Pump Management Panel installed.Photo: Future house  battery locker is forward of galley. The site is originally occupied by drawer & small locker.Photo: Clearing out the space for the house battery box.Photo: house bank battery box complete & painted.Box has space for six 6V batteries = 660AHPhoto: New battery box with four 6V batteries plus a spacer on left occuping space for two additional 6V batteries.Photo: DIY Junction Box for mast wiring.  Box  will be mounted under counter top in the head.Photo: Below Head Sink:Macerator is mounted below sink.  The cut out above the macerator will be used for wires leading to the mast.  The covered panel above the cut out houses the wiring for the macerator and mast wiring.Photo: Experimenting with various electrical panel layouts.Photo: test fitting electrical panel templates behind new panel frames at nav station.Photo: Holes for wire runs cut outboard of nav station seat (lower right). Once the wiring is complete, we plan to enclose this area with storage / arm rest.Photo: test fitting new panel for nav station electrical & electronicsPhoto: test fitting for new eletrical & instrument panels at nav station.Photo: forward instrument panel hinges downward and aft electrical panel hinges forward.Photo: From left to right:Two dc neutral bus bars Two dc positive terminal blocksInstrument / NMEA fuse blockAC terminal block; (top)AC neutral & ground bus (bottom)Photo: installing terminal blocks, fuse blocks, and bus bars in electrical panel.Photo: Components for by  for my DIY fuse block... Starboard, BlueSea Bus, ANL Fuses, and 5/6" fasteners.Photo: Laying out the location of posts in alignment with the posts on the bus barPhoto: Drilled out counter sunk holes in starboard block and installed 5/16" machine screws with threads exposed on top side.Photo: Inserted fuses between a couple posts to locate distance between terminals.Photo: Used countersink #10 machine screws inserted below to secure the bus bar and terminal block to the base.Photo: Example of how system will look with large guage wiring attached to terminals.The lower wire, labled "B" is the feed from the house battery bank.The other three wires will connect to... the engine alternator, the starter battery Automatic Charging Relay (ACR), and the battery selector switch panel.Photo: Double ANL Fuse blockPhoto: Installing DIY ANL fuse block at Nav StationPhoto: Primary DC+ fuse block and DC- Bus located below the new electrical panel at Nav Station.Photo: Plexiglas cover over primary DC fuse blockPhoto: Installing 12V primary wiring and components at Nav StationPhoto: All the pieces in place but need to refinish the fiddle and teak trim prior to final assemblyPhoto: Locker under nav station seat contains starter battery, battery & bilge pump management panel, and automatic charge relay (ACR) for start battery.Photo: fabricating a mounting board for the house bank's DC shunt, switch, and ANL Fuse.Photo: House bank DC Shunt, On/Off Switch, and 300A ANL Fuse accessible via cabinet door below salon seat.Photo: Re-used face from original drawer under salon seat to provide access to house bank on/off switch and fuse.Photo: Looking down on completed house battery bank.   Plan to increase size by two additional batteries prior to departing on extended travels.Photo: both lids on house battery bankPhoto: Terminal Block and DC Neg Bus in locker forward of nav station.Photo: Electrical Panel and house raw water strainer in locker forward of Nav StationPhoto: Plastic Starboard Cover over electrical block and bus in locker forward of Nav StationPhoto: Pilgrim's new battery charger.  Charger is sized to work in conjunction with our portable Honda Generator.Photo: Primary DC Fuse Block InstallationPhoto: Battery charger and inverter installation completePhoto: New battery charger and inverter installed in  quarterberth area.Photo: Instrument Panel with addition of inverter controler (bottom row second from left.)Photo: Progress on Pilgrims nav station.Photo: Installing plug end of new Smart Plug 30A shore power kit.Photo: Wiring the electrical panel's 120V AC terminal blocks and buses complete.Photo: AC Wiring on back side of AC selector switch.  Box mounted below switch is Pro Safe Galvanic Isolator.Photo: AC Power source  rotary  switch installed on bulkhead aft of electrical panel.  Switch allows user to select between (inverter, off, shore power).  Photo: beginning to install DC circuits in panel.Photo: Properly sized and organized breakers with labels in Pilgrim's panel.Photo: All the wiring from the electrical panel to the buses and terminal blocks completed.Photo: All the wiring from the panel is now installed. Photo: The backside of Pilgrim's new electrical panel.Photo: Wiring AC junctions in galley sub panel box.Photo: cover installed on back side of galley sub panel