A windlass is an essential component for boats equipped with anchors and chain rode, offering a mechanical advantage that eliminates the need for manual hauling. For those planning to install a windlass themselves, proper preparation, installation, and wiring are crucial to ensure functionality and longevity. This article provides a detailed guide to windlass installation, focusing on tools, deck preparation, alignment, wiring, and sealing techniques based on verified data from multiple sources.
Preparation and Requirements for Windlass Installation
Before beginning installation, it is essential to evaluate the boat and its existing infrastructure to ensure compatibility with the windlass. The primary requirements include:
- Bow Roller: A self-launching bow roller is ideal for guiding the rode smoothly into the windlass. The path from the bow roller to the windlass gypsy must be straight and clear to avoid unnecessary strain on the windlass components.
- Chain Locker Space: The boat must have sufficient chain locker space under the bow to accommodate the rode. For horizontal windlasses, at least 12 inches of vertical clearance is required, while vertical windlasses need approximately 18 inches of clearance.
- Deck Thickness: The deck thickness must be suitable to accommodate the windlass components both above and below the deck surface. For example, the Anchorlift Barracuda windlass requires a deck thickness between 3/4” and 1 1/2”. If the deck is thicker, adjustments or consultation with the manufacturer may be necessary.
Additionally, the ground tackle (anchor and rode) must be compatible with the windlass. Windlasses are specific about the type and size of rope and chain they can handle. It is recommended to ensure that the rope is spliced directly to the chain rather than using a shackle, as shackles may not pass through the windlass mechanism.
Tools and Supplies for Installation
The following tools and supplies are typically required for windlass installation:
- Pencil and Measuring Tools: For marking and measuring.
- Drill and Drill Bits: To create mounting holes.
- Hole Saw and Rasp: For cutting and shaping the deck.
- Wrench and Allen Wrench Sets: Metric sizes may be necessary depending on the windlass model.
- Pliers and Wire Snips/Crimps: For handling and preparing wires.
- Dremel (Optional): For fine adjustments and sealing.
- Heat Shrink Tubing or Liquid Electrical Tape: For waterproofing electrical connections.
- Wire Routing Clamps: To secure and organize wiring.
- Epoxy and Marine Sealant: For sealing the windlass and mounting holes.
- Marine Grease: For lubricating moving parts.
- Thread Locker: For securing bolts and preventing loosening due to vibration.
These tools are essential for ensuring a secure and long-lasting installation. Proper preparation with these materials will help avoid delays and complications during the installation process.
Deck Preparation and Mounting
Mounting the windlass begins with careful planning and preparation of the deck. A template provided by the manufacturer should be used to mark the location of the windlass. The gypsy must be aligned directly with the bow roller to ensure the rode runs within a 10-degree angle, minimizing strain and wear.
Before drilling, it is important to verify that there are no obstacles beneath the deck. Horizontal windlasses require at least 12 inches of fall for the rode beneath the deck, while vertical windlasses require closer to 18 inches. If the deck has a curvature that could misalign the windlass components, shims should be installed to maintain parallelism between the above-deck and below-deck portions.
Drilling should be done with the correct bit size. For example, the Anchorlift Barracuda windlass uses 8mm bolts, so a 10mm bit should be used to create the mounting holes. After drilling, the mounting holes should be sealed, especially if the deck is a sandwich construction. A Dremel can be used to bore out the core material, and the hole should be filled with epoxy resin followed by a layer of epoxy to prevent water intrusion.
Sealing the windlass itself is also critical. A bead of marine sealant or caulk should be applied around the base before installation. Once the above-deck portion is in place, the bottom portion (such as a backing plate for horizontal windlasses or the motor for vertical windlasses) must be aligned and secured. The motor should be positioned away from the rode pathway, and the shaft must be aligned with the keyway in the gearbox. The deck bolts should be aligned with the gear box flange, and the assembly should be pushed firmly to the underside of the deck. Thread locker and stainless hardware should be used to secure the bolts.
Before fully tightening all nuts, it is important to allow the sealant to cure. This prevents damage to the seal and ensures a watertight installation.
Aligning the Windlass and Gypsy
Correct alignment of the windlass and gypsy is critical for the smooth operation of the anchor system. The gypsy must be in a straight line with the fall of the anchor and rode to the bow roller. Any deviation can cause excessive strain on the windlass and issues with the feed of the rode.
In some cases, it may be necessary to adjust the position of the anchor hawse pipe to accommodate the windlass. A template of the original hawse pipe hole can be used to cut a new hole that matches the original. The old hole can be sealed using a plug made from the cut-out section of the deck. The plug should be coated with thickened epoxy and slid into the hole. A layer of fiberglass bi-axial should be applied on both the top and bottom of the deck to reinforce the area and prevent cracking around the plug.
Proper planning and alignment will ensure that the anchor and rode drop straight into the deepest portion of the anchor locker when passing through the windlass. This helps to prevent tangling and ensures efficient storage.
Wiring and Electrical Considerations
The electrical wiring for an electric windlass must be carefully planned to ensure safe and reliable operation. Electric windlasses typically require a power input of 1000 watts or more, which translates to over 80 amps at 12 volts. This high current demand necessitates the use of heavy-duty cables with large cross-sections—typically 35 to 50 square millimeters.
For medium-sized boats, it may be beneficial to install a separate battery near the bow, which can be charged by the alternator via an isolating relay. A sealed AGM battery is recommended for sailboats due to its resistance to heeling. This setup reduces the strain on the main battery and ensures a stable power supply for the windlass.
The wiring itself should be sized according to the distance and current draw. For example, the Anchorlift Barracuda 600 windlass requires 4-6 AWG wire if the circuit length is up to 24 feet, and 4 AWG if the length exceeds 24 feet. A circuit breaker should be installed to protect the windlass from electrical faults.
Depending on the windlass model, it may be a two-wire or three-wire motor. These are wired differently, so it is important to follow the manufacturer’s instructions. Switch gear such as a helm switch, foot switch, and remote control can also be added to provide flexibility in operation.
Wires should be supported approximately every 18 inches to reduce flex and entanglement caused by boat movement. All wire connections must be waterproofed using heat shrink tubing or an alternative method to prevent water damage.
Sealing and Final Steps
After the windlass is mounted and wired, it is important to seal all components to protect against water intrusion. The windlass itself should be sealed with marine sealant, and the mounting holes should be filled with epoxy to prevent water from entering the deck's core materials.
The windlass shaft and gearbox bushing should be greased with marine grease, and the gearbox and motor should be coated with an anti-corrosion spray before installation. This helps to extend the life of the windlass and prevent rust and corrosion.
Once all components are in place and sealed, the windlass can be tested to ensure it operates smoothly. The circuit breaker should be checked, and all wiring should be inspected for secure connections and waterproofing.
Conclusion
A properly installed windlass is a valuable addition to any boat, providing convenience and reducing the physical effort required to handle anchors and rode. By following the steps outlined in this guide—careful planning, deck preparation, alignment, wiring, and sealing—boat owners can ensure a functional and durable installation.
It is important to consult the manufacturer’s manual for specific instructions related to the windlass model being installed. Additionally, all electrical work should be done with caution to ensure safety and compliance with marine standards. With the right tools, materials, and preparation, a windlass can be installed successfully and used reliably for many years.