Electrical and Navigational Systems
Planning a Complete Marine Electrical System Before Running Wire
A reliable marine electrical system starts with planning, not wiring. In this video, I walk through the six critical steps for designing an electrical system from scratch for a sailboat or trawler, including calculating electrical loads and amp-hour requirements, creating a wiring plan and schematic, budgeting the system, and determining locations for batteries, solar, inverters, AC/DC panels and other components. I also cover using mockups and templates to plan electrical lockers and helm stations, deciding when to purchase components, preparing panel locations before installation, and incorporating ABYC standards and best practices into a DIY boat electrical system.
Building a Custom Boat Helm Pod for Modern Marine Electronics
Older sailboats and trawlers often need a new helm pod when the original instrument box cannot accommodate modern navigation electronics or interferes with the steering and engine controls. In this video, I show how I design and fabricate a custom helm pod using cardboard patterns and PVC foam board, including sizing the enclosure for Garmin and Simrad electronics, gauges, VHF radio, switches and a rudder indicator. I also cover instrument ventilation, working around throttle and gear-shift clearance, dealing with asymmetrical boat geometry, and using the screw-and-glue method to fabricate the new helm enclosure.
Planning Marine Electronics and Electrical Panels for a Boat Helm
Before installing marine electronics, the helm needs to be laid out so displays, switches, gauges, electrical panels and controls all fit without interfering with one another. In this video, I use full-size templates and mockups to plan the placement of navigation electronics, switches, gauges, autopilot controls and AC/DC electrical panels before cutting or wiring anything. I also cover planning 12-volt DC and 120-volt AC panel locations, checking clearances around steering and engine controls, organizing gauges throughout the boat, and using mockups to prevent expensive mistakes when designing an electronics and electrical layout for a sailboat or trawler.
Choosing and Installing a Marine AC/DC Electrical Panel
Choosing the right marine electrical panel requires matching the panel to the number and type of circuits your sailboat or trawler actually needs. In this video, I compare Paneltronics and Blue Sea Systems marine electrical panels and show how an electrical load budget and circuit plan determine panel size and configuration. I then install a Paneltronics 3402 combination 120V AC / 12V DC master panel, covering panel placement, recessed mounting, helm-station fit, circuit planning and ABYC considerations before the boat’s electrical wiring is installed.
Installing a SmartPlug Shore Power Inlet and ELCI Protection
Upgrading an older sailboat or trawler shore-power system can improve both reliability and electrical safety. In this video, I relocate and install a stainless-steel SmartPlug shore power inlet, prepare the fiberglass hull for the new connector, and explain why I chose SmartPlug over a traditional twist-lock shore-power plug. I also cover ABYC shore-power requirements, ELCI breaker protection, connector placement, fire prevention, and planning a safe 120-volt AC shore-power installation as part of a complete marine electrical refit.
Installing a 12-Volt Marine Air Horn System with Relays and Compressors
Installing an electric air horn on a sailboat or trawler requires more than simply connecting the horns to 12-volt power. In this video, I test vintage Hadley marine air horns and build a compact 12V system using electrically activated air compressors, air canisters, solenoid valves, pressure switches and electrical relays. I compare direct-drive and piston-style compressor systems, troubleshoot air leaks and electrical activation, and test the vintage Hadley setup against a modern 12-volt air horn kit. The project shows the practical electrical and pneumatic components required to install and operate marine air horns on a boat.
Planning Lithium Batteries and Components for a Marine Electrical System
Designing a modern electrical system for a sailboat or trawler becomes considerably more complicated when LiFePO₄ lithium batteries, high-output alternators, solar charging and multiple charging sources are involved. In this video, I explain the problems I encountered while planning the complete marine electrical system, including electrical load calculations, lithium battery-bank sizing and placement, component compatibility, AC/DC panel locations and ABYC requirements. I also explain why I ultimately hired a professional marine electrical consultant to review the system design and help develop a coordinated electrical component plan before purchasing components or beginning the final wiring installation.
Choosing a 12-Volt Marine Refrigerator for a Sailboat or Trawler
Choosing a 12-volt refrigerator for a sailboat or trawler means balancing power consumption, reliability, construction quality and cost. In this video, I compare a budget 12V RV/marine refrigerator with an Isotherm Cruise Elegance 85L marine refrigerator, including differences in build quality, price and shipping damage. I also test refrigerator performance using a 12-volt lithium battery, measure real-world cooldown performance, and discuss 12V DC versus 120V AC operation and whether paying more for a name-brand marine refrigerator makes sense for a cruising boat electrical system.
Building a Simple 12-Volt Electrical System for a Small Sailboat
A small sailboat doesn’t need an overly complicated electrical system. In this video, I show how to design and install a simple 12-volt marine electrical system for a small sailboat, including battery switching, electrical panel layout, navigation and masthead lighting, and accessory circuits. I also cover ABYC wiring practices, making clean electrical-panel cutouts, and using HDPE plastic to fabricate an inexpensive custom mounting panel. It’s a practical approach to building a clean, reliable 12V electrical system for a small sailboat restoration or refit.
Planning Marine Electrical Outlets, Switches and Bulkhead Cutouts Before Wiring
Before running wire in a sailboat or trawler, electrical outlets, switches, boxes and bulkhead penetrations need to be planned and cut in advance. In this video, I show how I lay out and cut openings for 120V GFCI outlets, 12V switches, electrical boxes and marine electrical controls throughout a boat before the wiring installation begins. I also cover switch placement for electric toilets and shower sumps, cutting fiberglass and Coosa board, selecting tools for clean electrical cutouts, and why completing this fabrication work first can prevent problems when installing the final 12V and 120V marine electrical systems.
Electric Boat Propulsion: Real-World Range, Batteries and Charging
How practical is electric propulsion for a cruising boat? In this video, I spend 16 days and travel more than 200 nautical miles aboard a Greenline 33 electric trawler in Norway, testing a 50 kW Torqeedo electric drive with a BMW lithium battery bank, solar charging and shore-power charging. I cover real-world electric boat range, cruising speed, battery consumption, charging times, noise levels and the effects of weather and current on energy use. It’s a firsthand look at how a modern electric propulsion system performs in actual cruising conditions and how electric power compares with conventional diesel propulsion.
How to Stop Water Entering Boat Engine Room Vents
Engine-room ventilation needs to provide adequate airflow without allowing rain, spray or boarding water into the engine compartment. In this video, I show how I upgraded the engine-room vents on an older trawler by replacing the original plastic vent covers and fabricating custom fiberglass dorade boxes to help separate water from incoming air. The project covers marine engine-room ventilation, preventing water intrusion, fiberglass fabrication with epoxy and WEST SYSTEM products, and improving vent protection while maintaining airflow for the diesel engine and onboard systems.
Where to Find Rare, Vintage and Obsolete Boat Parts
Finding rare or discontinued boat parts can stop a classic boat restoration when the original hardware, engine component or replacement part is no longer manufactured. In this video, I visit Marine Sales & Repair near Detroit and meet Earl “the Pearl” Stilson, one of the remaining old-school boat-parts dealers specializing in used, vintage and hard-to-find marine components. His inventory includes vintage Chris-Craft parts, Hercules marine engine components, rare engine gaskets, bronze hardware, teak handrails and decades of used marine equipment. He has a lifetime of engine repower knowledge. For anyone restoring an antique powerboat, classic fiberglass sailboat or older trawler, marine salvage yards and longtime used-parts dealers can be an important source for obsolete marine engine parts and boat hardware that conventional suppliers no longer carry.