Bensen Windlass Replacement

Discussion in 'Modifications/Customizations' started by Iprof, Jun 9, 2009.

  1. Iprof

    Iprof Member TECHNICAL Contributor

    815
    Aug 8, 2008
    Lake Simcoe
    A 300 DA 4kw Gen-set, central vac, electric head, windlass, AC/reverse heat, Lowrance 522ci GPS Char
    twin 5.7 with Alpha drives
    I anchor out a lot over the summer and this summer I have a 6 weeks trip planned for the North Channel and we won't spend much time at a marina. The Benson all rope rode still works good but I need to have chain/rope rode. I will be using 100' chain and 100' or rope. This will do for the places I anchor and most of the time I won't use more that the 100' of chain. Here are a few pictures of the install.
    Here is the Bensen and the V700 side by side.

    [​IMG]
    The new windlass does not use the same holes as the old one but I knew that. The teak pulpit was also in need of sanding and re-oiling.
    [​IMG]
    Lay out, lay out, lay out you can't afford to make one mistake.
    That's a 4 1/2" and a 2 1/2" hole saw.
    [​IMG]
    I measured it 5 times, checked and rechecked every thing.
    Here are the 2 new holes and I made plugs from the 4 1/2" hole that I drilled.
    [​IMG]
     
  2. Iprof

    Iprof Member TECHNICAL Contributor

    815
    Aug 8, 2008
    Lake Simcoe
    A 300 DA 4kw Gen-set, central vac, electric head, windlass, AC/reverse heat, Lowrance 522ci GPS Char
    twin 5.7 with Alpha drives
    Here is the windlass dry fitted to make sure every thing is perfect. Notice the teak has been sanded and ready for the oil.
    [​IMG]
    Here are the plugs installed in the pulpit. They both turned slightly as I hammered them in. I know that the plugs will be seen but they sure look better that a piece of stainless over them.
    [​IMG]
    Here it is fitted, sealed and bolted into place. I'm just waiting for the acetone to evaporate and then the oil.
    [​IMG]
    Here is the finished product 4 coats of teak oil. I will connect the power in the morning and install the rode and the anchor.

    [​IMG]
    This was a project that I was looking forward to and an very happy with the finished job.

    I will post a few pictures with the anchor and the chain installed later.

    Ken
     
  3. Sundancer

    Sundancer Active Member

    Jul 20, 2005
    Prosser, WA
    30 year old CLASSIC 300 DA, towed almost anywhere behind the Duramax Duallie Crew Cab.
    16 cyl, 700 cu. in./Alpha I's
    Ken:

    Great job! I'm not sure I could stomach cutting a hole that big in my pulpit! My windlass is 16 years old and will be heading for college in a couple of years. I might have to break down and add one at that point! Do you get enough drop in the locker to handle the rope and chain? It seems like it would need to be a little farther back but I haven't ever seen another boat like mine that has a windlass!

    I agree that the teak plugs look better than any other patch! They are natural and it says something about the owner and the care to plug those holes the right way! I can't wait to hear how it works!

    Great post!!
     
  4. Iprof

    Iprof Member TECHNICAL Contributor

    815
    Aug 8, 2008
    Lake Simcoe
    A 300 DA 4kw Gen-set, central vac, electric head, windlass, AC/reverse heat, Lowrance 522ci GPS Char
    twin 5.7 with Alpha drives
    Thank you for the kind words. I did measure the drop and there is lots, the V700 needs 12" and the locker is a lot deeper than 12". I did move the windlass back but not much, 3 inches. I did not have time today to get the electrical connected, I will tomorrow afternoon. I noticed a leak into the cabin at the base of the anchor locker, the inside material is wet at that point. I will sand it and apply some resin and some gray paint to the inside and how that fixes that little problem. I also noticed that there are 2 screws that hold the mirror in place from the anchor locker and they don't look like they every hand any sealant applied to them I will seal that while I am at it. I am re-using the bensen wiring switches and circuit breaker, I will keep the new items and replace the old ones only if needed. I should be able to post pictures by Saturday of the final set-up. The size of the holes scared me also but this is my 3rd install of a windlass and the second Lewmar, the first was a Sprint 600 and if is still working on the Grew 238 I installed it on with out any problems and that was 8 years ago.

    Ken
     
  5. Iprof

    Iprof Member TECHNICAL Contributor

    815
    Aug 8, 2008
    Lake Simcoe
    A 300 DA 4kw Gen-set, central vac, electric head, windlass, AC/reverse heat, Lowrance 522ci GPS Char
    twin 5.7 with Alpha drives
    Rode Anchor Install

    Saturday I finally got around to installing the 200' of chain and rope. I used a claw anchor on my last boat and it never slipped once. We shall see how it holds the SR after 4 or 5 weeks on the hook.
    [​IMG]

    [​IMG]

    We went out Saturday night and I let out 100' of chain and was able to retrieve the anchor without any problems. The V700 worked great and I would recommend it to one that needs to replace a windlass.

    Ken
     
  6. JJCOTTE

    JJCOTTE New Member

    46
    Jun 20, 2010
    Hudson River.. Hudson, NY
    1987 300 Weekender Raytheon Radar Garmin GPS...
    Twin 350 Mercruiser Inboards
    Hi Ken
    My Benson is done and i am going to install a Lewmar in its place and your install looks sweet so I am planning on doing it the way you did yours. Can you tell me what in Gods name I need to do to get this thing off? I removed the cover topside, removed the wood screws that hold the topside section down and I took the 3 nuts that are 3/4 off the rope locker side. I do not see any set screw in the rope grab and even though I tapped on the shaft I can't make it move. Any Advise would help greatly
     
  7. 88dancer300

    88dancer300 New Member

    653
    Feb 14, 2010
    new england coast
    1988 Sundancer 300, Heat/AC,gennie,central vac,Ice maker stretched swim platform, monster stereo sys
    Twin 5.7 liter 260hp closed cooling system Mercruisers with Alpha one drives.
    Ken, Nice job ! I just replaced mine 2 weeks ago. I used a stainless Lewmar 700 above deck model that I removed from my last boat. I also used all of the Benson wiring, relays and switch. It works great. I had the same concern about the drop, but it retrieves just fine. I like the teak plugs too. I ended up making a 3/8 thick teak plate to cover all of the old holes, the teak under the Benson just did not sand up nice enough. Dave
     
  8. 88dancer300

    88dancer300 New Member

    653
    Feb 14, 2010
    new england coast
    1988 Sundancer 300, Heat/AC,gennie,central vac,Ice maker stretched swim platform, monster stereo sys
    Twin 5.7 liter 260hp closed cooling system Mercruisers with Alpha one drives.
    JJ, You will need to remove the pulley from the shaft to get the motor and gear box out. There is a set screw in the v of the pulley, but if looks like mine did, you will never get it out. I used a 6 inch long 3/8 drive extension, and tapped the shaft out of the pulley. It came right out. Another problem is that sea ray bolted the motor to the boat, then istalled the pulpit, and then installed the capstan. So when you remove the nuts and motor out of the locker, you will be left with three long bolts that you can not remove because the heads are between the hull and the pulpit. I had to cut them off with a sawzall. STUPID idea for the install ! Dave
     
    Last edited: Jul 15, 2010
  9. Air O'Nautical

    Air O'Nautical Active Member

    Feb 5, 2008
    Stamford CT "Ponus Yacht Club"
    1995 400EC. Raymarine E80,4kw dome, Garmin 235 gps,
    2013 7.4L Mercruiser Blue water.
    Hurth straight shaft 630's,
    Westerbeke 7.0 BCG
    Re: Rode Anchor Install


    Looks great nice job.
     
  10. speakrdude

    speakrdude Member

    998
    Feb 21, 2009
    Northwest Arkansas
    2002 Sea Ray 340 DA
    Raymarine C80 Tri Data
    twin 6.2 MX MPI
    Do you wnat to get rid of the old one? I have a boat with the lower have only of the old Benson.

    Jim
     
  11. 88dancer300

    88dancer300 New Member

    653
    Feb 14, 2010
    new england coast
    1988 Sundancer 300, Heat/AC,gennie,central vac,Ice maker stretched swim platform, monster stereo sys
    Twin 5.7 liter 260hp closed cooling system Mercruisers with Alpha one drives.
    Sorry, I already gave the old Benson to another CSR member.
     
  12. KatzNDogs

    KatzNDogs New Member

    79
    Apr 26, 2010
    Long Island, NY
    2001 310 Sundancer (current)
    1988 300 Weekender(Sold)
    1987 268 Sundancer (sold)
    Twin 350 MIE Horizon's
    I'm starting one of these today I'll be sure to post pictures and the results!
     
  13. Molson

    Molson Active Member

    Aug 5, 2011
    Midland, ON
    1997 330 DA
    Twin 7.4 carb V-Drives
    Apologize for bringing up this thread from the dead. Do you recall the wiring size the benson had? I too have a Benson, and am ordering a Lewmar Pro 1000. It is calling for 6 or 8 AWG (depends on my wire run). I would splice in the new contactor and breaker, but would love to use the wiring.

    Currently the boat has two separate switches (up / down) and I'd keep them if possible.

    Thanks!
     
  14. david leonard

    david leonard New Member

    25
    Jul 11, 2018
    1989 Sea Ray Sundancer 300, Raymarine C120
    2 (lord help me) 5.7 Mercs
    i'm doing mine on Sunday. pray for me!
     
  15. david leonard

    david leonard New Member

    25
    Jul 11, 2018
    1989 Sea Ray Sundancer 300, Raymarine C120
    2 (lord help me) 5.7 Mercs
    hi, there. i know it's an old thread, but i'm in the middle of this, right now, and having a dreadful time with the pulley. my set screw was in fine shape, so i removed it. there is a key in the shaft--as i'm sure you know. can't get that out. i used a 6 inch drive extension, and hit it with a hammer so many times, my wrist is sore. should i be using a bigger hammer? help!!! my email is davidleonard2@verizon.net.
     
  16. Goin3Wide

    Goin3Wide New Member

    10
    Jul 23, 2018
    1986 Sundancer 27' Twin 4.3 2009 Merc's
    Twin 4.3 2009 Merc's w/ Alpha 1 drives
    Hello, if you would still be able to discuss this project, I have a Benson that I'm exactly int he middle of, and your coaching would be invaluable. Please advise if you have the interest to share knowledge, thanks !!!
     
  17. bobeast

    bobeast Dance the Tide SILVER Sponsor

    524
    Oct 22, 2017
    Isleton, CA
    2002 310DA
    350 MPI w/V-drives
    I just helped remove the motor from one of these this past weekend. The trick for us was to apply penetrating oil to the top of the shaft, and then let it sit for about an hour. Then we just tapped it out with an extension. It took a few strong whacks but each tap pushed it down a little further until it finally dropped out.

    At the risk of asking the obvious, you did remove the three large nuts holding the motor to the underside of the pulpit, right?
     
  18. Goin3Wide

    Goin3Wide New Member

    10
    Jul 23, 2018
    1986 Sundancer 27' Twin 4.3 2009 Merc's
    Twin 4.3 2009 Merc's w/ Alpha 1 drives
    62248961-467C-4B95-998E-850279888716.jpeg 50D26F54-061E-4B03-9A4E-7742271BD322.jpeg 62248961-467C-4B95-998E-850279888716.jpeg 50D26F54-061E-4B03-9A4E-7742271BD322.jpeg
     

    Attached Files:

  19. Goin3Wide

    Goin3Wide New Member

    10
    Jul 23, 2018
    1986 Sundancer 27' Twin 4.3 2009 Merc's
    Twin 4.3 2009 Merc's w/ Alpha 1 drives
    Yes. Nuts removed. So I’m up to hammering the shaft from the top. Is this my best plan? Shall I apply loosening oil around the shaft?
     
  20. bobeast

    bobeast Dance the Tide SILVER Sponsor

    524
    Oct 22, 2017
    Isleton, CA
    2002 310DA
    350 MPI w/V-drives
    Yes. a good penetrating oil helped us. Your pictures still show the nut attached however.
     

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