RUDDER KIT INSTRUCTIONS

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RUDDER KIT INSTRUCTIONS
PAMLICOS-120,140,135T, 145T, 160T, Excel
Rotomolded Pamlico 120, 140, 135T, 145T, 160T, Excel
The addition of a rudder to a kayak results in additional control
and efficiency, especially in certain sea and wind conditions.
The presence of a rudder is, by no means essential, nor does
it mean it must be deployed at all times. A rudder is not a
substitute or replacement for paddling experience or ability.
Caution: All possible precautions have been taken to provide
for a successful installation of your new rudder but installation
DOES require permanent alteration of your kayak. Please read
all instructions prior to beginning the process. Be safe, measure
twice before proceeding with any step requiring drilling or
cutting of your hull. If you are uncomfortable with any part
of this process, we suggest you contact your local dealer for
support and advice. It is possible they will undertake this
installation for you at a modest cost.
All directions included in these instructions reference starboard
(right), port (left), forward, stern, etc., are given as if you are
standing behind your kayak looking forward.
As these models very, so may the images presented.
ADDITIONAL TOOLS & MATERIALS NEEDED
Phillips Head Screwdriver
Cable Cutters
Drill with 5/32” & 5mm Drill Bit
11/32” Wrench
Cigarette Lighter
Small Tube of Lexel, or
(equivalent marine sealant)
Deep 7/16” Socket
Measuring Tape or Ruler
Crimpers
Scissors
Non-permanent marker
REVISION
1.0
DATE
4/20/05
Rivet Gun
INSTALLING THE RUDDER SYSTEM
Step 1-4
INSTALLING THE RUDDER
The rudder system consists of the rudder assembly, rudder mounting
bracket, rudder rest to secure the rudder blade when stowed on deck,
rudder uphaul line to provide for deployment and retrieval of the rudder
blade, and the steering system to allow rudder to be angled right or left
to guide kayak.
STEP 1: INSTALLING THE RUDDER BRACKET
1
Remove the two filler screws from the stern of the kayak and
discard.
2
Remove the split ring from the rudder pin and remove the
bracket assembly from the rudder.
3
Install a lock washer on both hex head bolts and slide the bolts
into the rudder bracket, placing a small amount of Loctite®
adhesive on the bolt threads.
4
Step 2-1
With the stop pin of the rudder bracket facing upwards, start
the bolts into the stern. Tighten the bolts securely using a 7/16”
deep well socket, making sure the bracket stays flush against the
stern and straight up and down. (illustrated in step 1-4 to the
right)
STEP 2: INSTALLING THE RUDDER REST
There are two rudder rest systems used on kayaks covered by this kit.
Locate your boat model below and follow appropriate procedure. Note
that necessary parts for either installation are included with this kit
V-block (Pamlico 120, 140, 145, 160/Excel): (Illustration 2-1)
1
2
Place the V-block rudder rest on the raised flat V-block mounting
panel on the stern deck 12”+/- forward of stern. Center the Vblock on the mounting panel so that the center notch is aligned
with the seam bisecting the kayak deck.
Using the holes on the sides of the block, mark and drill holes
using the 5mm drill bit. Push rivets through holes on block
and then through drilled holes in deck and secure with rivet
gun. If rivet does not snap off on first trigger pull, release
trigger and push head of rivet gun flush against the rivet
flange and pull again. If rivet does not break off flush, tamp
rivet lightly with small hammer to knock down.
Integral Bungee/Carry Handle (Pamlico 135T):
1
Rudder rest is factory installed on all Pamlico 135T. Note
bungee cord loop sewn to the molded stern carry handle. To
release bungee, lift cord off of single pad eye across from carry
handle. To secure, hook bungee over catch on single pad eye.
STEP 3: INSTALLING RUDDER UPHAUL LINE AND RUDDER
The uphaul line allows you to raise and lower the rudder and will be
routed along the top of the deck along the right side of the kayak. It will
run from the rudder to a ?tting near the cockpit, guided by a number of
round pad eyes.
1
Unroll the up haul cord attached to the rudder. Place the rudder
in the rudder bracket (do not install split ring) and lay out the
up haul cord along right side of hull.
2
Inspect the right (starboard) side of hull up along the deck.
Depending on model, you will find:
REVISION
1.0
DATE
4/20/05
Pamlico 120, 140: Mark position on starboard side of
deck approximately 2” aft of, and slightly below “Pamlico”
model name decal. Drill 5mm hole at mark.
Pamlico 145, 160, Excel: Measure 2” towards stern from
Pamlico 160 logo and in line with logo. Drill 5mm hole at
mark.
Pamlico 135: Locate two pad eyes securing starboard side
of stern deck bungee. Center round pad eye between and
1” below bungee pad eyes. Drill 5mm hole at mark.
3
Locate pad eye at forward end of uphaul line:
Pamlico 120, 140: Locate “Wilderness Systems” logo on
starboard side of hull. Measure 8” towards stern and mark
location. Center a pad eye over mark and oriented parallel
to keel line. Mark the two mounting holes and drill with
5mm bit.
Pamlico 145, 160, Excel: Locate stern mounting bolt for
seat runner along starboard side of cockpit. Measure 7”
towards stern from bolt and mark. Center pad eye oriented
parallel with keel line over mark and mark 2 mounting
holes. Drill each mounting hole with 5mm bit.
Pamlico 135: Locate stern seat bolts on starboard side.
Measure 20” forward of front bolt and 2” down from
crease defining cockpit coaming. Mark and center pad eye
over mark, oriented with keel line. Mark 2 mounting holes
and drill each with 5mm bit.
INSTALLING THE RUDDER SYSTEM
Step 3-12
4
Insert 8-32 x 5/8” pan head screw through stern most mounting
hole in pad eye and then through drilled stern most hole in hull.
Start nylon lock nut onto screw but do not tighten.
5
Loop end of uphaul loop under pad eye and set loop inside
raised center of pad eye. Make sure one adjusting turtle is above
pad eye and other is below. (Illustration 3-5)
6
Start 8-32 x 5/8” pan head screw through front mounting hole
of pad eye and secure with lock nut.
7
Tighten both lock nuts securely.
8
Return to hole drilled in step 2 above between rudder and
cockpit. Insert 8-32 x 5/8” pan head screw into center of round
pad eye and insert into deck.
9
Make sure uphaul lines are not tangled or crossed and align
lines with cut outs in perimeter of round pad eye.
10
Secure round pad eye with lock nut and tighten.
11
Make sure the rudder is stowed and centered. Slide the topmost
turtle forward as much as possible.
12
Draw the knot in the up haul line (not the bungee) out of
the top turtle and remove the slack without moving the
turtle and tie another knot in the line to absorb excess line.
(Illustration 3-12)
13
Repeat process to remove the slack in the turtle in the lower up
haul line.
14
Step 3-5
Step 4-5
Release the rudder and test the up haul line’s functionality. Pull
the lower turtle forward to lift and deploy rudder and top turtle
forward to raise and stow rudder. Familiarize yourself how turtle
position corresponds to rudder position. For maximum safety,
paddlers should know rudder position by feel not sight.
STEP 4: INSTALLING THE STEERING SYSTEM
The rudder steering system consists of a pair of cables running from
the rudder up to and connecting with the foot pedals. The cables are
routed inside the hull of the kayak below the deck and on each side
of the seat. Solo/Tandem models (Pamlico 135, 145, 160/Excel) also
include extension system to allow rudder to be operated from stern or
centered seat.
1
Locate the rudder steering cable ports (the raised “frogeyes” on
deck or side of hull.)
Pamlico 120/140: on either side of deck, 10 1/2” forward of
stern.
Pamlico 135: on either side of hull, 9” forward of stern.
Pamlico 145: on either side of deck, 10 ¼” forward of stern
Pamlico 160/Excel: on either side of deck, 11” forward of
stern.
2
Remove the rudder from the rudder bracket for ease of drilling
access and set it aside.
REVISION
1.0
DATE
4/20/05
Step 4-7
INSTALLING THE RUDDER SYSTEM
REFER TO THE FOLLOWING PAGE FOR VISUAL
INSTRUCTIONS
3
Take great care in drilling! These steps are difficult to correct!
Drill 5/32” hole through flat stern face of frog eyes. On deck
mounted frog eyes, angle drill bit slightly down towards keel
line. On hull mounted frog eyes, angle drill bit in towards keel
line. Drill at approximately a 20o to 25o angle. Avoid drilling
into angled forward face of frog eye.
4
5
Reinstall the rudder assembly and install the split ring on the
bottom of the rudder assembly post to secure rudder assembly
to bracket.
Footbrace assemblies:
marine sealant to tube passing through bulkhead to eliminate
possibility of leakage.
9
Pamlico 160/Excel: Route the tubing forward and through
the large hole in the seat.
10
Slide new pedal strap assembly onto stern and center (if
applicable) rudder tracks.
11
Align mounting hole of guide loop over mounting hole on
stern end of rudder track Secure guide loop with #14 x 5/8”
Phillips Trusshead screw.
12
Slide stern footbrace all the way forward on the track. If
necessary, adjust the length of the foot pedal strap via the
tabler buckle.
13
Pamlico 120/140: Cut the cable tubes 5” shy of the ring of
the foot pedal straps.
Pamlico 120, 140: Remove existing footbrace assemblies and
discard.
Pamlico 135, 160/Excel: Remove the existing stern and central
footbrace assemblies and discard.
Pamlico 145: Locate indent (punch mark) in hull 28 ¾” from
center rail stern screw head. Place stern mounting hole of
additional foot brace track over mark to accommodate solo
paddling position. Use track as template to locate front and
center mounting holes. Drill 5mm” hole at each mark.
Insert #14 x ¾” Phillips truss head screws through hull at
each hole. Position track so that raised stop is at forward end.
Thread screws into backside of new runner track. Partially start
stern screw until track is engaged. Then start forward screw,
followed by center screw. Alternate tightening screws until track
is secure.
Pamlico 135, 145, 160/Excel: Repeat for new center footbrace
track. (Illustration 4-5 on preceding page)
6
Starting at stern frog eye, feed the straight (un-flared) end of
the nylon tubing forward. Reach behind cockpit or through
stern hatch and pull the tubing forward towards the cockpit.
7
Pamlico 120/140: Locate the stern most half pad eye on the
deck rigging in front the rear oval hatch on each side. From
inside of the hull, remove the nylon lock nut from the stern
mounting screw. Clip the 1/8” cable clamp over the nylon tubing
and place mounting hole over the exposed screw. Secure with
original lock nut. (Illustration 4-7 on preceding page)
Pamlico 135, 145, 160/Excel: Locate the bow most half pad
eye on the deck rigging on each side. From inside of the hull,
remove the nylon lock nut from the stern mounting screw. Clip
the 1/8” cable clamp over the nylon tubing and place mounting
hole over the exposed screw. Secure with original lock nut.
8
Pamlico 120, 140: If your boat is equipped with bulkhead, drill
¼” hole within 1” of top of bulkhead to feed tubing through
bulkhead. Position hole to allow as straight a run in tubing from
connection just installed to side of seat. Apply “dab” of Lexel or
REVISION
1.0
DATE
4/20/05
Pamlico 120, 140, 135, 145: Route tubing between side of
seat and hull.
Pamlico 135, 145, 160/Excel: Trim the tubing 2 inches
forward of hole in seat.
14
Uncoil rudder cables. Remove rings from pins on wings on
each side of rudder head. Insert pin through eyelet on rudder
cable, then through hole in wing and secure with split ring.
Eyelet on rudder cable should be positioned on top of wing.
15
Feed into tubing through frog eyes and work forward until
end extends beyond end of tubing.
16
Slide shrink wrap and 2 ferrules over end of cable and push
back against tubing.
17
Route cable through ring on pedal strap, extend 2” beyond
ring and align with balance of cable. Cut cable.
18
Slide both ferrules over cut end of cable and position about
½” apart. Firmly crimp both ferrules multiple times to firmly
secure cable.
19
Slide shrink wrap over both ferrules and heat to shrink tightly
over both.
20
Adjust the foot pedals to desired positions by releasing or
tightening strap at the tabler buckle. Use the same procedure
to tension the rudder cable to avoid unnecessary slack.
INSTALLING THE RUDDER SYSTEM
Important Instructions for using a tandem boat with rudder from
solo paddling position.
Pamlico 135, 145, 160/Excel
1. Slacken the foot pedal strap to allow access to screw securing guide loop
Remove screw and guide loop from end of track.
2. Remove foot pedal by sliding off stern end of foot pedal track.
3. Unthread strap from tabler buckle at pedal assembly.
4. Install pedal on center track. Install guide loop on stern end of center track
using existing hardware.
5. Clip hook on end of extension strap onto ring on end of original strap
6. Thread opposite end of extension strap through guide loop on center strap
and through tabler buckle at foot pedal.
7. Adjust pedal position for proper position and fit.
8. To restore tandem paddling position, reverse above sequence of instructions.
11
5
10
20
19
12
FULLY
ASSEMBLED
17
HULL
5”
16
REVISION
1.0
DATE
4/20/05
19
2”
TESTING THE RUDDER SYSTEM
TESTING THE RUDDER SYSTEM
STEP 5: SUPPORT THE BOAT BEFORE TESTING!
1
Position the kayak so that it will safely bear your weight
and the rudder will not contact the floor or ground when
deployed. You may wish to set the kayak on a deck with the
stern extending over the edge or to put the kayak in calm
water to test its operation.
2
Remove the bungee cord securing rudder on the rear deck.
Grasp the uphaul line at the turtles and test deployment
and stowing of rudder.
3
With the rudder deployed and the kayak safely supported, sit
in kayak and place your feet on the rudder pedals. Pushing
one pedal forward while relaxing pressure on the other
makes the rudder pivot to the side pushed. Reversing the
foot pressure makes the rudder swing to the other side.
4
With your legs equally extended, check to see that the
rudder is in a neutral position, aligned with the centerline
of the kayak.
5
Be aware that the presence of a rudder requires new
precautions when launching and landing your kayak. Keep
the rudder stowed on deck with the bungee cord released
when launching or landing, since contact with underwater
objects or the bottom may bend the rudder blade.
6
Use extra care to avoid personal injury when handling your
boat with a rudder installed. The rudder has sharp edges
compared to hull.
7
Always secure rudder blade when transporting your kayak.
Always release rudder from rest when launching. Restraining
bungee cannot be reached while paddling.
COMPLETED
ASSEMBLY
(Pamlico 160T Shown)
REVISION
1.0
DATE
4/20/05
G
MF
PART# 3580-7231
REVISION
1.0
DATE
4/20/05
C.
. IN
.007" Gap Fill
High Strength
Seals Refrigererants
NET 1 ml.
2N7
ON
4
R
HE
Item No. 342701
PARTS LIST