(PLEASE CONTACT YOUR LOCAL DEALER or CUSTOMER SERVICE FOR WARRANTY INFORMATION)

Transcription

1 RUDDER KIT SOLO AND TANDEM KAYAKS IMPORTANT: For Tandem kayaks, the Supplemental Kit will be needed in addition to this kit and can be purchased through a registered dealer. The addition of a rudder to your Wilderness Systems kayak will result in added control and course efficiency as well as be an additional aid in staying on course in rough conditions. The Course Control rudder system is designed for maximum efficiency and minimal drag and is injection molded of a high impact plastic hybrid material that is stiff yet very durable and is impervious to corrosion. This kit is designed to enable the installation of a rudder on all current Wilderness Systems solo kayaks as well as many earlier models that were designed to accommodate a rudder and feature a flat vertical stern. With rudder ready current models, installation is pretty straightforward and close to a plug and play process. With older models, more creativity will be required though we have made efforts to include all components that might be needed to complete installation. It s certainly possible that additional components may be required (especially on older models). Safety Note: Installation of a rudder on any kayak will require the drilling of a number of holes in your hull and deck. Proceed carefully and subscribe to the measure twice / drill once process (PLEASE CONTACT YOUR LOCAL DEALER or CUSTOMER SERVICE FOR WARRANTY INFORMATION) Notes: Wilderness systems has been producing kayaks since the 1980 s and in keeping with our unrelenting pursuit of improvement we have used multiple rudder systems over the years, sometimes on same model kayaks which remained in production for many years. This kit is intended to allow the installation of a rudder on as many Wilderness Systems kayak models as possible but no one kit can address every possible model. It may be necessary to obtain additional hardware or fittings to complete a specific installation. One example of change over time is the development of inserts positioned in the hull. These are threaded receptacles molded into the hull to accept screws. Earlier models will not have this improvement and in those cases installation will be reliant on rivets inserted in the hull. It is possible on some models for earlier editions to require rivets while newer models have been modified to accept threaded inserts. It is likely that you will have components or hardware left over after installation. This is the result of our intention to accommodate as many different kayak models as possible with this kit. IMPORTANT NOTE: It is recommended to lay out the hardware prior to starting the installation and confirming quantities provided.

2 RUDDER PARTS CHECKLIST SOLO KIT (Parts not to scale)

3 RUDDER PARTS CHECKLIST TANDEM KIT (Parts not to scale)

4 Tools Required: #2 Philips head screwdriver 3/8 Box or open end wrench Electric Tape Measuring tape or ruler Scissors or Knife Drill with 3/16 bit 5/16 bit (Threshers & ATAK models only) Rivet Gun (possible, depending on age & model) INSTALLATION INSTRUCTIONS: (STEP 1): ATTACHING THE RUDDER BRACKET (For models with molded-in rudder mounts): Skip this step and move directly to Step 2. Rudder Bracket (QTY: 1) Socket Head Screws 1/4-20 x 5/8 (QTY: 2) Lock Washer, ¼ (QTY: 2) Hex Key Wrench (QTY: 1) 1. Place ¼ lock washer on each socket head screw. 2. Place one screw on end of hex key wrench. 3. Remove filler screws from inserts at stern of kayak and discard. 4. Slide one screw with wrench attached into hole in molded rudder bracket. 5. Position bracket so that the raised knob is on top and align with inserts in stern. 6. Partially thread one screw into insert; do not tighten fully. 7. Place second screw on hex wrench and insert through bracket and into second insert. 8. Thread to start screw. 9. Position bracket so that the rudder pin hole is vertical. 10. Hold bracket in this position and fully tighten both screws. (STEP 2): INSTALLING RUDDER ASSEMBLY Rudder Blade Assembly (QTY: 1) Instructions for kayaks using the bolt-on rudder bracket: 1. Unwrap lift lines from rudder assembly. If rudder split ring is attached to post, remove ring. 2. Insert silver rudder post into vertical hole in bracket. 3. Install split ring in hole in base of rudder post. 4. Rotate rudder blade up and over so that it is resting position on top of deck. If the blade doesn t rest flush in the groove on top of deck, gently bump the rudder down until it settles in groove. Instructions for kayaks with molded-in rudder mounting hole: (Example: Polaris Series) 1. Discard split ring. 2. Rotate rudder assembly so that blade is horizontal and extends beyond the stern of the kayak. This will position the flat side of the rudder post towards the bow of the kayak. 3. Insert assembly into rudder mounting hole. 4. Rotate assembly 180o to the left to lock rudder in place. 5. Spin assembly around so that blade is resting on deck. If not flush to deck, see #4 above.

5 (STEP 3): Installing Rudder Swivels Rudder Swivel, w/set_scrw - (QTY: 2) Washer, NEO, 1/4 X 5/8 - (QTY: 2) Rudder Split Ring,5/8 - (QTY: 2) 1. Insert the Rudder Swivels from the bottom of the holes located on the aluminum wings of the blade assembly. 2. Next, snap a rubber washer over the exposed nipples that are visible on the top side of the wings. 3. Thread the split rings through each of the small holes located on the side of each nipple but above each rubber washer. Once the rings are in place, the swivels should be secured to the wings (see image below). (STEP 4): INSTALLING RUDDER TIE DOWN Rudder blades need to be secured to the deck in order to be transported safely. The lock down system will vary from model to model. The most common systems are: For Tarpons, Rides, and some other sit-on-top models with stern tank well bungees: Lift the rear cross bungee up and over top of rudder blade to secure in place. For Threshers, Focus, and most sit-ins as well as Ride X and some sit-on-tops: Deck Fitting (QTY: 1) Phillips Head Screw, x 3/4 (QTY: 1) Neoprene/Stainless Combination Washer, #10 x 5/8 (QTY: 1) Cap Nut, (QTY: 1) J-Hook Fitting, black (QTY: 1) Bungee Cord, 3/16 x 1 ; Black (QTY: 1) Rudder Rest, V Block (older models) (QTY: 1) Rivets,ALUM (older models) (QTY: 2)

6 1. Most models will have a molded-in groove on deck to align the rudder blade. Look to side of this groove and identify a molded recess in deck that can be within 5 of stern of kayak to 15 forward of stern (position will vary depending on model). Some models may have an insert in place. If so, remove filler screw and skip #2 below) 2. Use 3/16 bit and drill hole at center of recess. Access under side of deck via stern hatch where needed. 3. Thread bungee cord through the deck fitting and tie off with overhand knot. 4. Insert screw into fitting and secure to deck with washer and cap nut on underside of deck if no insert or directly to insert. Position washer so that the black neoprene side is on top in contact with deck. Tighten fully. 5. Slide J-hook over opposite end of bungee cord. 6. Stretch bungee up alongside rudder blade and allow to retract until the J-hook captures top edge of rudder blade and bungee cord is under sufficient tension to hold blade firmly against deck. 5 of bungee is usually a workable length but confirm on your kayak before cutting. 7. Tie off bungee at this point with an overhand knot and cut off excess bungee cord. Singe ends with flame to prevent fraying. Older Models: If there is no molded groove in deck, align rudder blade straight and parallel to keel line. Place the V rudder rest under the blade, approximately 3-4 from end of blade. Check to make sure it sits well on deck and that there is enough play in the bungee to slide up and over rudder blade to secure to deck. Mark the holes in base and drill 3/16 holes at marks. Secure rudder rest with star rivets provided. (STEP 5): Install Lift Line Control Fittings will vary depending on model and age of kayak. Some models will have a deck loop installed on right side of deck next to cockpit whereas others may only have a recess in deck to indicate position. Position should be just behind or even with your hips when seated in kayak. If no fitting in place: Round Pad Eye, black (QTY: 1) Flat head Phillips head screw, #10-32 x 1 (QTY: 1) Neoprene/Stainless Combination Washer, #10 x 5/8 (QTY: 1) Cap Nut, (QTY: 1) Rudder Deployment Line Turtle Line (with 2 turtles on bungee) (QTY: 1) If deck fitting is not in place: 1. Locate recess on side of hull as described above. If no recess evident, determine position by sitting in boat and finding a comfortable position to pull forward or backwards on line extending from rudder. 2. Drill 3/16 hole at desired position. 3. Thread bungee on Turtle assembly through guides on base of round pad eye and position pad eye over drilled hole. 4. Secure with screw and interior hardware. 5. Tighten fully and test to make sure Turtle assembly will slide back and forth and is not pinched by pad eye. If Deck Fitting or Filler Screw is in place: 1. Loosen and remove stern most screw on two screw fittings or loosen center screw is a single screw fitting sufficiently to allow 3/16 bungee cord to slide under fitting. 2. Slide the bungee on the Turtle Assembly under end of fitting and position so that it can slide forwards and back. 3. Tighten loosened screw(s). (STEP 6): INSTALLING THE LIFT-LINE SYSTEM The actual number of round pad eye locations will vary with kayak model and length. Depending on date of manufacture, some kayaks will also have molded in inserts at round pad eye locations with filler screws. If no inserts, it will be necessary to drill 3/16 holes at those locations and secure with interior hardware. On other models, access to the interior of the hull may be so limited to require the use of rivets. Parts Needed (number will vary by model): Round Pad Eye, black - (QTY: 2 to 4) Flat head Phillips head screw, #10-32 x 1 - (QTY: 2 to 4) Neoprene/Stainless Combination Washer, #10 x 5/8 - (QTY: 2 to 4) Cap Nut, (QTY: 2 to 4) 1. Locate molded in recesses along right side of deck along the parting line separating hull from deck. Check from stern of kayak forward to right side of cockpit. 2. If locations have inserts, back out filler screws and set aside. If no inserts, drill at center of recess with 3/16 drill bit. 3. Secure a round pad eye at each recess using above hardware. For locations without inserts, secure pad eyes with washer (neoprene side against hull) and cap nut on interior of kayak. Access locations via cockpit and/or hatches. Position pad eyes so that the line channels are oriented parallel to the keel line of the kayak, allowing line to run straight and true from rudder forward.

7 4. Thread lines from rudder assembly forward through round pad eyes, threading left side line through the top channel and the right side line through the bottom channel. Do not twist lines, they need to run clean through pad eyes and be easily pulled forward and back. 5. Confirm that the rudder is centered over stern deck. 6. Thread the top lift-line through the open hole in the top Turtle. Position Turtle 3 ½ behind the deck fitting installed in Step 4. Tie lift-line off with an overhand knot. Pull the knot into the hole in the Turtle. 7. Thread the bottom lift-line through the bottom hole in the other Turtle. Slide this Turtle towards stern until there is tension in the bungee. Secure Turtle in that position via an overhand knot in the lift-line and pull line back into Turtle. 8. Trim off excess line from each Turtle and sear the raw ends of the lift-lines to prevent fraying. 9. Make sure rudder blade is released from hold-down and test the lift-line action. Pull the stern most Turtle forward and the rudder blade should deploy to vertical position. Pull the opposite Turtle to raise the blade to resting position on kayak deck. (STEP 7): INSTALLING ALUMINUM FOOTBRACE EXTRUSIONS Aluminum Footbrace Extrusions, Black (QTY: 2) Screw, Phillips Truss Head, ¼-20 x ¼ (Sit-In models) (QTY: 2) Screw, Phillips Truss Head, ¼-20 x 5/8 (2 for most models /4 for ATAK) (QTY: 4) Washer, Neoprene/Stainless Combination, ¼ (Thresher 140 & 155) (QTY: 2) Nut, Lock, 1/4-20 (Thresher 140 & 155) (QTY: 4) Screw, Phillips Truss Head, x 3/4 (Select Models) (QTY: 2) Screw, Phillips Truss Head, x ½ (Select Models) (QTY: 2) Nut, Lock, (Select Sit-On-Top Models) (QTY: 4) Washer, Neoprene, ¼ x 5/8 (QTY: 4) Washer, Lock, Toothed (some models see step 8 below) (QTY: 2) Washer, Stainless/Neoprene, #10 x 5/8 (QTY: 4) Screw, Phillips Truss Head, x 7/8 (some models) (QTY: 2) 1. Secure rudder centered on stern deck. 2. Remove existing footbraces from hull. 3. Install metal extrusions: Sit-Inside Kayak Models: At forward end of extrusion use ¼-20 x 1/2 screw with neoprene washer between screw head and kayak hull. At stern end of extrusion use the longer ¼-20 x 5/8 screws with neoprene washer. Holes in extrusions are tapped to accept 1/4-20 threaded screws. No nuts needed. Sit-on-Top Kayak Models (Threshers and ATAK see below): Some models and some locations will have molded-in inserts, others will rely on internal washer and nut (depends on the access to interior of hull). Some older models of the Ride have threaded inserts rather than 1/4-20. Test thread of insert to identify correct screw. Position extrusion and secure front end with x ½ Phillips Truss Head screw, #10 x 5/8 combination washer, and lock nut. Secure end closest to seat with x 3/4 Phillips Truss Head screw set into insert if present. No washer required. Thresher and ATAK: Drill out threaded holes in metal extrusions with a 5/16 drill bit. ATAK: Secure foot brace extrusions with 4 ¼-20 x 5/8 screws. Threshers: At insert locations, secure extrusions with ¼-20 x 5/8: screws. At locations without inserts, use ¼-20 x 1 screws secured on the interior of hull with ¼ washers and ¼-20 lock nuts provided. 4. Tighten hardware securely to secure extrusions to hull. (STEP 8): INSTALLING FOOTBRACES Keepers Footbraces (Right & Left) (QTY: 1 each) SPECTRA CORD, 1.8MM (QTY: 22 FT) 1. Attach Spectra rudder cord to the end of each Keepers footbrace using a Bowline knot to secure (see image below). IMPORTANT NOTE: If installing system on sit-inside model, attach the Spectra cord to the footbraces first before inserting them into the metal extrusions.

8 Bowline Knot in Four Steps: 2. Identify the raised stopper molded into one end of the Keeper footbraces. Slide footbraces (with pedals installed) into extrusions so that the stopper is at front end of extrusion. 3. If not installed, slide foot pedals onto molded footbrace runners. The raised stopper on end of runner will be on the bow end of the footbraces. Slide foot pedals in place so that triggers face towards the bow. 4. Secure rudder centered in rudder rest. NOTE: Some editions of some models (ex: Ride 135) are designed such that the foot brace runner can slide out of stern end of footbrace extrusion. Test your boat to see if it is so affected by lifting the bow and watching to see if foot brace exits stern end of extrusion. If so, this can be prevented by installing a toothed washer onto a x 7/8 Phillips truss head screw. Insert screw into recessed hole in center of footbrace rail and tighten until snug. This will act as a brake to prevent the runner from sliding out of extrusion. (STEP 9): INSTALLING THE SPECTRA CORD & CONNECTION TO HEAD OF RUDDER ASSEMBLY If your kayak is rudder-ready (produced from 2011 forward) the tubes to guide the Spectra cord are already installed. Follow the instructions below. If your kayak is older or not rudder-ready it will be necessary to first install the tubes. Follow the advice provided at the end of this step. Rudder-Ready Kayaks: 1. Remove the plugs at each end of rudder tubing (at stern of kayak and behind the seat on each side. 2. Insert Spectra cord into the tube opening in cockpit area and feed it through. Continue pushing until end of cord emerges from tubing close to the rudder blade assembly at the kayak rear/stern. 3. Holding end of cord, slide one footbrace as forward as possible pulling the Rudder Cord forward as well. In same step, turn Rudder Blade Assembly so that it is in the correct position according to the footbrace position (Example: if sliding left footbrace forward, Rudder Blade should be positioned to the left. NOTE: The wing on the rudder head should not contact the stern of the kayak when the footbrace is fully extended. 4. Once rudder position is acceptable, run Spectra cord back to the appropriate swivel fitting located on the Rudder wing for that specific side. 5. Insert loose cord ends into pilot holes on Swivel fittings and pull to remove slack. 6. Hold footbrace while pulling cord to keep pressure on line. 7. While holding cord taught with slack removed, tighten set screw on Rudder Swivel to lock cord in place. 8. Tie double over hand knot in the extra cord ends to serve as a safety stop (Leave extra cord to allow later adjustments if needed). 9. Repeat for opposite side. (image of Step 10 completed below)

9 Non Rudder-Ready Kayaks: Parts Needed (if older non-rudder-ready model): Tubing,NYLON, #11, 5/32 x.106 (older models) (QTY: 20 FT) Cable Clamp,NYLON, 3/4 Blk (older models) (QTY: 4) Inspect the stern of the kayak and look for any raised bumps or recessed flat surfaces, one on each side of hull or deck of kayak. These are the stern cable ports and need to be drilled out with 3/16 bit. Insert tubing into port and push/pull forward. You want to run a tube on both sides of the underside of the deck on either side of hatches, etc. The run of the tubing should be as straight as possible with no sharp angles or bends. Cable clamps are supplied with this kit to hold the tubing on the underside of the deck, using existing deck fitting screw locations to guide the tubing forward. It may be necessary at some times to replace the existing screw with a longer screw (not included in kit) or add additional cable clamps, again depending on length of kayak. You don t want the tubing to sag noticeably but it does not have to be drum tight either. At the cockpit on Sit-On-Top kayaks, you will drill a 3/16 hole in the rear of cockpit on each side aligned as close as possible with the stern end of the footbraces. On Sit-In kayaks with stern bulkheads, you need to drill a 3/16 hole on each side of bulkhead to route the tubing through the bulkhead. Again, position holes so that the tubing run is as straight and level as possible. HINT: Be careful pulling the tubing forward so that you don t pull it through the stern port accidentally. Once installation of tubing is complete, follow Spectra cord process in STEP 10.

10 (STEP 10): TESTING THE RUDDER SYSTEM Test the lift line system operation while sitting in kayak to familiarize yourself with relative positioning of the Turtles and the rudder blade. You should be familiar enough with system to be able to tell rudder position by feeling the Turtles and not having to turn around and visually confirm rudder positioning. Test the steering system while sitting in kayak, pushing one pedal forward and then the other. If you are new to paddling a ruddered boat, you ll need to get used to a fluid foot pedal system as compared to the fixed position system you likely had prior. Get used to the feeling of pushing forward with one foot while allowing the other to move close to your seat. To brace the kayak, you ll need to get used to applying equal pressure on each foot pedal. With this rudder system, the foot pedal and footbrace runner move together, sliding within the metal extrusion. Most paddlers adjust the foot pedal position so that it is in a centered position when the rudder is also centered. User Cautions: Always secure rudder blade in stowed position when transporting your kayak and always remember to release rudder blade from tie down prior to launch. The rudder is designed to kick up if it encounters an obstruction but it still makes sense to be cautious when approaching the shore or in shallow water. The more impact the blade encounters with an obstacle, the increased chances the blade could be bent or damaged before it can kick up. The addition of a rudder makes handling the stern of the kayak more awkward when moving the kayak. Make sure the rudder blade is secured in stowed position and that access to carry handles is not impeded. Beware of sharp edges on the blade or rudder head assembly. The addition of a rudder to a kayak positioned upside down on a vehicle roof lowers the clearance below the kayak by about 5 to 6. Check for clearance while walking behind vehicle or opening trunk or hatchback. The Course Control Rudder System is designed to be low maintenance. The biggest threat to proper operation is potential for sand and grit to accumulate in the foot brace extrusions. Periodic rinsing of these areas with fresh water will eliminate this issue. Please visit the Wilderness Systems website for more information or contact our Customer Service Department with any questions.