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Bennett Bolt Extension Cables

Old 02-04-2019, 05:04 PM
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Default Bennett Bolt Extension Cables

Transom to helm is 17 ft. - 25 ft. pilothouse.

From what I've surmised and in discussions with tabman a while back, I'll need to buy extra wiring since there's zero chance most boats can use the wiring out of the box (too short). Either you're lengthening #4 in the diagram or you're lengthening the two #2 runs.

2x either BAW2015 or BAW202 is ~$80
This would put the relay module behind the dash and have no connectors/breaks in the wiring as it runs under gunnel to the pilothouse
Amazon Amazon

or

Probably 2x BHW4010 is ~$80
This would have a break in the wiring somewhere under the gunnel (possible water intrusion) but would put the relay box closer to the transom
Amazon Amazon

or

I'm so tempted to cheap out and just splice in some ancor 16/2 AWG into the blue/yellow run and lengthen them myself for a few bucks. Good connections and some adhesive lined heat shrink....ridiculously bad idea????
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Old 02-04-2019, 05:57 PM
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No Sir not at all!! If it was me I'd not use the supplied connectors and just use the mentioned heat shrink connectors, especially at the transom, and make the runs as long as you need. We did this when we installed them on my brother's boat last year and it worked perfect. We used 14 ga wire. I just helped my neighbor install his Bolts two weeks ago and he had plenty of wire from Bennett to get to the CC on his 25' Mako.
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Old 02-04-2019, 06:13 PM
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For not much more you can order a 30' or 40' replacement cable (#4 in the diagram) right from Bennett or one of its suppliers. I ordered a 30' just recently.
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Old 02-04-2019, 07:26 PM
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Originally Posted by bobeast View Post
For not much more you can order a 30' or 40' replacement cable (#4 in the diagram) right from Bennett or one of its suppliers. I ordered a 30' just recently.
Tabman gave me sku's for longer ones (you can figure them out) but can't find them for sale anywhere.
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Old 02-04-2019, 07:43 PM
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Originally Posted by starbright55 View Post
Tabman gave me sku's for longer ones (you can figure them out) but can't find them for sale anywhere.
Here ya' go.

https://www.hodgesmarine.com/searchr...arness&Submit=
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Old 02-04-2019, 07:50 PM
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Originally Posted by starbright55 View Post

I'm so tempted to cheap out and just splice in some ancor 16/2 AWG into the blue/yellow run and lengthen them myself for a few bucks. Good connections and some adhesive lined heat shrink....ridiculously bad idea????
Not at all.

I'm not a big fan of the Deutsch connectors. Pain in the a$$ pulling them thru rigging tubes. I always cut them off and use heat shrink butt connectors. Even at the switch panel.
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Old 02-04-2019, 08:32 PM
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Originally Posted by starbright55 View Post
I'm so tempted to cheap out and just splice in some ancor 16/2 AWG into the blue/yellow run and lengthen them myself for a few bucks. Good connections and some adhesive lined heat shrink....ridiculously bad idea????
Hope not because that's what I did. No problems yet. And I am an EE.
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Old 02-04-2019, 08:55 PM
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Catch22, why are you cutting off the Deutsch connectors? They are easily taken apart and reassembled after pulling.

Starbright, you could either do as you mention and cut and extend the actuator wires, but now you have two splices per cable that could possibly fail. The other option is to order the tool and connectors and make your own. I just did this on my boat when replacing actuators. The previous owner has simply cut off the plugs and used butt connectors.

You can probably find these items at a lower cost, but I am in Bahrain, so I need shipping also. This site was my best option.

I ordered this tool at $37.87
https://deutschconnectorstore.com/pr...ct-crimp-tool/

And a few of these connectors kits at $2.68 each. There are also options for connector kits with a lip for heat shrink, or gold plated vs nickle plated terminals. You can also order the kit with solid terminals for 14-16awg vs the 16-20awg pins if you decide to run 14awg instead.
https://deutschconnectorstore.com/pr...onnector-kits/

Amazon has a tool also for less, but the connectors I found were more.
https://www.amazon.com/gp/product/B01N3P2S17/ref=ox_sc_act_title_2?smid=A1UMBRA5ZTBCX8&psc=1 https://www.amazon.com/gp/product/B01N3P2S17/ref=ox_sc_act_title_2?smid=A1UMBRA5ZTBCX8&psc=1
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Old 02-04-2019, 09:02 PM
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"now you have two splices per cable that could possibly fail "

Connectors fail far more often than properly made splices.
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Old 02-04-2019, 09:20 PM
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Originally Posted by GaryDoug View Post
"now you have two splices per cable that could possibly fail "

Connectors fail far more often than properly made splices.
Exactly.
I'll take a heat shrink connector, over a modular connector any day.
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Old 02-05-2019, 08:44 AM
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Originally Posted by bobeast View Post
Bob, those are for electronic indicators that go with hydraulic systems. EIC is for hydraulic while BHW is the prefix for the BOLT system.
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Old 02-05-2019, 09:23 AM
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Sometimes, it just takes a phone call - Bennett said even though at BHW 4010 (10') is the longest listed on the website, they will make custom lengths to 60'. I might get a quote for one but then again, $15 worth of wire and I'm probably good splicing....

Last edited by starbright55; 02-05-2019 at 09:35 AM.
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Old 02-05-2019, 09:27 AM
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Originally Posted by starbright55 View Post
Bob, those are for electronic indicators that go with hydraulic systems. EIC is for hydraulic while BHW is the prefix for the BOLT system.
oops. sorry about that. Definitely don't want to mislead.
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Old 02-07-2019, 12:07 PM
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starbright55,

Hi! My name is MJ Thomas and I am the Client Service Manager here at Bennett Marine.

The main issue you need to keep in mind when dealing with 12 VOLT wire harness runs that are using “working amperage” to operate your trim tabs is the overall length, since at 35’ or longer you are going to start having voltage drop issues that will prevent the trim tab system from working as designed. Our standard BOLT trim tab sets (BOLTxxxx) include two (2) “20 Ft Bolt Act Wire Ext cables (BAW2020), which when combined with the 6’ leads that are included on our BOLT Actuators you will have an overall length run of 26’ or so. This reduces the chances of voltage drop becoming an issue with our basic BOLT trim tab systems.

Now, if the overall length of the wire harness runs is going to be 35’ or more, then we would suggest relocating the BOLT Control Box closer to the stern and use one of our Helm Keypad Wire Ext cables (BHW40xx, we offer this in 3’, 5’, 7’, 10’ and then in 5’ increments up to 60’) to complete the wire harness run between the trim tab controls & the Control Box.

I wasn’t able to determine the part number for the kit you purchased; so do you have the part number for the kit? If so, please let me so we will have a better idea of your situation?

We look forward to your reply.

Regards,M.J. Thomas
Client Services
Bennett Marine
A Division of Yamaha Marine Systems, Inc

550 Jim Moran Blvd
Deerfield Beach, FL
tel: (954) 427-1400
fax: (954) 480-2897
MJ_Thomas@Yamaha-Motor.com
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Old 02-12-2019, 04:30 PM
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Originally Posted by BennettTrimTabs View Post
starbright55,

Hi! My name is MJ Thomas and I am the Client Service Manager here at Bennett Marine.

The main issue you need to keep in mind when dealing with 12 VOLT wire harness runs that are using “working amperage” to operate your trim tabs is the overall length, since at 35’ or longer you are going to start having voltage drop issues that will prevent the trim tab system from working as designed. Our standard BOLT trim tab sets (BOLTxxxx) include two (2) “20 Ft Bolt Act Wire Ext cables (BAW2020), which when combined with the 6’ leads that are included on our BOLT Actuators you will have an overall length run of 26’ or so. This reduces the chances of voltage drop becoming an issue with our basic BOLT trim tab systems.

Now, if the overall length of the wire harness runs is going to be 35’ or more, then we would suggest relocating the BOLT Control Box closer to the stern and use one of our Helm Keypad Wire Ext cables (BHW40xx, we offer this in 3’, 5’, 7’, 10’ and then in 5’ increments up to 60’) to complete the wire harness run between the trim tab controls & the Control Box.

I wasn’t able to determine the part number for the kit you purchased; so do you have the part number for the kit? If so, please let me so we will have a better idea of your situation?

We look forward to your reply.

Regards,M.J. Thomas
Client Services
Bennett Marine
A Division of Yamaha Marine Systems, Inc

550 Jim Moran Blvd
Deerfield Beach, FL
tel: (954) 427-1400
fax: (954) 480-2897
MJ_Thomas@Yamaha-Motor.com
Thanks for the reply.

I have, per the recommendations of Tom/Tabman:

BOLT Control With Indication (ELECTRIC SYSTEMS ONLY) - BCI8000
Bennett Hydraulic to BOLT Electric Conversion Kit - HYDBOLTCON
TPA1612UP (18 x 12's were a bit tight and Tom said these are WAY stronger than the standard tabs and worth the upgrade)

I am at work still (west coast time) and can't find my notes on my computer, but my recollection is that when I measured all of the wiring, it is no where near long enough to get to the helm of a 25' boat. I will update this with the exact lengths later when I get home.

Last edited by starbright55; 02-13-2019 at 09:30 AM.
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Old 02-12-2019, 08:23 PM
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Each cylinder has ~6 ft. of cable. These attach to the blue/yellow wires out of the control box. This will get me to the center of the transom, up high, where I plan on mounting the control box.



From the control box, there is 3 ft. of grey cable. On the end of the dash switch panel, there is ~32" of grey cable.





To summarize:

~6' of cable on each cylinder, ~3' of blue/yellow wire coming out of the control box - This allows the cylinders to be within ~9' of the control box with stock wiring. I am good here with the control box mounted high and centered on the transom.

~3' of grey cable from control box to plug, ~32" from plug to dash switches - This means the control box needs to be between 5-6' of the dash switches with stock out of the box wiring.

Again, there is no where near enough wiring for a 25' pilothouse - center of transom to helm is 19' (4' of beam plus 15' forward). Options are extending the blue/yellow wires (need two sets) and move the control box to the helm. Or, get a Helm Display Extension Cable custom ordered.



Last edited by starbright55; 02-13-2019 at 09:35 AM.
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Old 02-13-2019, 08:00 AM
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starbright55,

Ok, we are going to break down the components that are supplied with the part numbers you have provided, so that we are all on the same page for your application.

The first part number BOLT Control With Indication (ELECTRIC SYSTEMS ONLY) - BCI8000 is as follows:QTY
U/M
PART #
DESCRIPTION
1
EA
BCI8000
Bolt Control with Indication (includes following)
1
EA
BCI8500
BQE Display (BQEDISPLAY) Includes (4) EIC30 Thumb Nut, 8-32
1
EA
BCI8700
BQE Relay Module (BQERM) Include (2) ML63 Screw, SMS #8
1
EA
BQE122
BOLT CONTROL WITH INDICATION (BCI8000) INSTALLATION INSTRUCT
3
TOTAL PIECES
This kit is designed to work with our basic BOLT Trim Tab sets, which include the two (2) “20 Ft Bolt Act Wire Ext cables (BAW2020) and allows for these components to be mounted at the helm within 3’ to 6’ of each other (BCI8500 & BCI8700 each have 3’ leads for connection between each other).

The second part number Bennett Hydraulic to BOLT Electric Conversion Kit – HYDBOLTCON is as follows:QTY
U/M
PART #
DESCRIPTION
1
KIT
HYDBOLTCON
Hydraulic to Bolt Conversion Kit (includes following)
2
EA
BEA3000
Bolt Adjustable Actuator (BQEACTAJ)
1
EA
HYDBOLTRM12
*RM Conversion Hyd to Electric (RMCONV)
1
EA
HDWBQEUHB
HARDWARE, BOLT UPPER HINGE, ADJUST, BENNETT 2ACT. (HDWBQEUHB)
1
EA
HDWBQELHB
HARDWARE, BOLT, LOWER HINGE, BENNETT 2ACT. (HDWBQELHB)
1
EA
HDWWPC16PLG2
HARDWARE, WATERPROOF CON, SIZE 16, PLUG, 2 POS, QTY 2 (HDWWPC16PLG2)
1
EA
BQE126
Bolt Conversion Kit Instructions HYDBOLTCON
7
TOTAL PIECES
This kit was designed to convert OUR Standard Classic Hydraulic Actuator (single actuator per tab) & V-351 Hydraulic Power Unit 12V components to our BOLT Electric Trim Tabs by replacing both Classic Hydraulic Actuators, hydraulic tubing & V-351 Hydraulic Power Unit 12V on the vessel. Most of our Classic Hydraulic trim tab systems have the V-351 Hydraulic Power Unit mounted in the stern normally within 10’ or less from the Classic Hydraulic Actuators, so we expect the Relay Module Conversion Hyd to Electric 12V (HYDBOLTRM12) to be mounted right back in the same location as the V-351 Hydraulic Power Unit 12V there-by allowing the reuse of the 4-Color Wire Harness that connected between the V-351 Hydraulic Power Unit 12V & the helm controls. The BOLT Actuators have 6’ leads combined with the Relay Module Conversion Hyd to Electric 12V (HYDBOLTRM12) 3’ leads works out to 9’ total length runs to complete the connections between the transom Actuators and the Relay Module.

As you can see from the break downs above, these two part numbers were NOT designed to be combined. The main issue is the BQE Relay Module (BCI8700) overrides/replaces the Relay Module Conversion Hyd to Electric 12V (HYDBOLTRM12) in this application, since the BQE Relay Module (BCI8700) has trim tab indication capabilities that the Relay Module Conversion Hyd to Electric 12V (HYDBOLTRM12) does not have. So, for you to use these components to complete your installation, you will want to decide where to install the BQE Relay Module (BCI8700); at the helm or at the stern.

If you mount it at the helm, then you will want to order two (2) “20 Ft Bolt Act Wire Ext cables (BAW2020) to complete the connections between the BQE Relay Module (BCI700) and the two (2) BOLT Actuators on the transom. Of course, we do offer shorter length cables for this application (15’, 10’, 7’, 5’ & 3’), so all you do is change the last two (2) digits to reflect the length you want to order (I.E. 7’ cables, BAW2007).

If you mount it the stern, then you will want to order one (1) 25 ft Helm Keypad Wire Ext (BHW4025) to complete the connection between the BQE Relay Module (BCI700) and the BQE Display (BCI8500) at the helm. Of course, we do offer shorter length cables for this application (20’, 15’, 10’, 7’, 5’ & 3’), so all you do is change the last two (2) digits to reflect the length you want to order (I.E. 7’ cables, BHW4007).

We look forward to your reply.

Regards,M.J. Thomas
Client Services
Bennett Marine
A Division of Yamaha Marine Systems, Inc

550 Jim Moran Blvd
Deerfield Beach, FL
tel: (954) 427-1400
fax: (954) 480-2897
MJ_Thomas@Yamaha-Motor.com
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Old 02-13-2019, 01:55 PM
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Originally Posted by BennettTrimTabs View Post
If you mount it at the helm, then you will want to order two (2) “20 Ft Bolt Act Wire Ext cables (BAW2020) to complete the connections between the BQE Relay Module (BCI700) and the two (2) BOLT Actuators on the transom. Of course, we do offer shorter length cables for this application (15’, 10’, 7’, 5’ & 3’), so all you do is change the last two (2) digits to reflect the length you want to order (I.E. 7’ cables, BAW2007).

If you mount it the stern, then you will want to order one (1) 25 ft Helm Keypad Wire Ext (BHW4025) to complete the connection between the BQE Relay Module (BCI700) and the BQE Display (BCI8500) at the helm. Of course, we do offer shorter length cables for this application (20’, 15’, 10’, 7’, 5’ & 3’), so all you do is change the last two (2) digits to reflect the length you want to order (I.E. 7’ cables, BHW4007).
Yes, pretty much what I've determined. I will probably be ordering a BWH4020 which should be plenty of length.

Tom had suggested BOLTBLT instead HYDBOLTCON but BOLTBLT was not commonly available while HYDBOLTCON was and the online pricing was cheaper (try finding BOLTBLT online for sale anywhere or listed on Bennetts website - though I think Defender had it for $100 more than HYDBOLTCON ). He said HYDBOLTCON would work if you just discard the HYDBOLTRM12 and use the BCI8700 that comes with the BCI8000.

Can you confirm that if I had found and purchased BOLTBLT that I wouldn't be having this issue?
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