Old Town Castine Rudder - Manual

Old Town Canoe Co
CASTINE RUDDER KIT INSTRUCTIONS – FOR KAYAKS PRODUCED BEFORE NOVEMBER 2000
REPLACING KEEPER FOOTBRACES
Kit Contents: (1) Rudder assembly: Includes rudder, pivot bolt, split ring & cord
(2) Cable assemblies: Consisting of cable and cable tube
(1) 11”raising cord bungee with cord lock
(1) M Block
(2) Footbrace tracks and pedals w/ straps (2)
-20 lock nuts–
(2) Barrel Nuts (4) Swages –
(2)
-20 x 3/4" bolts
(5) Cable clamps
(2)
-20 x 1” bolts (large)
(4) Lg. Washers
(2) Stamped washers (1) Jam cleat
(1) Tube Aqua Seal (2) 10-24lock nuts
(3) Sm. Washers (9) Rivets
(2) 10-24 x 1” bolts (small)
THIS IS A GOOD TIME TO SORT OUT ALL THE PARTS AND SEPARATE THEM FOR EASY
ACCESS DURING ASSEMBLY. PLEASE READ INSTRUCTIONS THOROUGHLY BEFORE
BEGINNING THE RUDDER ASSEMBLY.
Required
tools: 3/16” Drill bit 3/8” wrench
1/4” Drill bit 7/16” wrench
Rubber Mallet Vice grips
Pop rivet tool Black Marker
Phillips head driver Tape Measure
Procedure
1. Install the rudder assembly by sliding the pivot bolt through the rudder mount at the stern
of the kayak. Secure the rudder by placing the split ring through the small hole in the end of
the pivot bolt. (Illustration #1)
2. On each side measure forward approximately16” along the parting line of the kayak from
the stern end. Make a mark 1” above the parting line. Drill 1/4” holes at these marks with
the holes angling down toward the front of the boat. (Illustration #2 and #3)
3. Push the straight end of the rudder cable and the black carrier tube through the hole you
just drilled. Keep feeding the black carrier tube through until only 2 1/4” of the black
carrier tube remains outside the hull. Place a small amount of aqua seal around the black
carrier tube, then slowly slide the black carrier tube into the hole until 1
” of the black
carrier tube is left. Place a cable clamp around the black carrier tube 1” from the end and
make a mark through the hole in the cable clamp, move the cable clamp slightly and drill a
3/16” hole. Anchor the cable clamp to the deck with a rivet and backup washer, then dab a
small amount of aqua seal onto the head of the rivet. Repeat for the other rudder cable and
black carrier tube assembly. (Illustration #3 and #5)
4. Measure 6 1/2” (?) from the stern end of the kayak and center the rear edge of the M block so
that the rudder can rest between the V notch of the M block when it is in the raised position.
Mark the location of the four holes on the deck; drill 3/16” holes and rivet the M block into
place. (NOTE: M Block cannot be used as a tie down point on kayak during
transportation.) (Illustration #2)
5. Drill two 1/4" holes through the foam bulkhead approximately 2” in from the parting line on
the kayak (the line made when the two halves of the mold come together). Push the rudder
cable and black carrier tube through the holes and seal with a small amount of aqua seal.
NOTE: Standard Egrets have no bulkheads. (Illustration #4)
6. Remove the nuts from the front bolts of the seat using the 3/8” wrench and the Phillips head
screwdriver. Put a cable clamp on each carrier tube, and then install the cable clamp on the