Madsu’s New Navigation Lights

Catalina 22’s of Madsu’s vintage had very awkwardly sighted navigation lights.

The bow light is actually behind the forestay and stem head fitting – not the best for visiblity.  And if I happen to have dropped the foresail on the deck, the light would usually get covered up. (See if you can even find the bow light in this picture of Madsu at the dock)

The stern light was a bit better, though mounted on the deck port-side, and not always visible.  While legal, these old lights have always made me nervous, particularly because I love night sailing.

So, before putting Madsu in the water this year I wanted to install new fore and aft nav lights, up on the pulpit/pushpit where they’d be seen.

Finding lights at Steveston Marine was easy – I got some nice Perko lights on sale – but mounting them on Madsu’s 1 inch pulpit and pushpit rails would be the challenge.

Catalina Direct sells a pulpit mount for over 30.00 dollars, and given the shipping and brokerage, it seemed like a crazy amount of money to spend.  So I decided to make my own (and spend a crazy amount of time to save a few bucks).

A few years ago I had purchased some stainless rail mount brackets (for a the traveler setup), and still had a few extra.

What I needed was some sort of plate to mount the lights on.  So, out came the jig saw and a piece of aluminum plate I had bought when I made the backing plates for the new winches.

I cut the plates, thinking I’d use 2 rail mounts on the bow light – but later opted to simplify with one (a good choice).  A little work with a grinder, then a file, then my Dremel tool, and the plates came out looking pretty great.

Next, I tapped holes for mounting the lights, and for securing the plate to the rail mounts.  I (and others) like to sit on the pulpit on a nice summer day, and with the mounting screws tapped, there’ll be no bolts protruding.

I wasn’t really up for drilling holes in the rail tubing and trying to chase the wiring through – I ran the wiring externally and secured it with self-amalgamating (rigging) tape.  If it turns out to be a nuisance, I’ll chase the wires inside the tubing next year.

Now I’ve got an additional level of comfort sailing at night, knowing that Madsu’s bow and stern light are visible.

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