RUDDER KIT INSTRUCTIONS

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1 C I N S T R U C T I O N S RUDDER KIT INSTRUCTIONS PAMLICOS-0,0,T, T, 60T, Excel Rotomolded Pamlico 0, 0, T, T, 60T, 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 Drill with / & mm Drill Bit Small Tube of Lexel, or (equivalent marine sealant) Measuring Tape or Ruler Crimpers Scissors Cable Cutters / Wrench Cigarette Lighter Deep 7/6 Socket Rivet Gun Non-permanent marker

2 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 : INSTALLING THE RUDDER BRACKET Remove the two filler screws from the stern of the kayak and discard. Remove the split ring from the rudder pin and remove the bracket assembly from the rudder. Step - 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. Step - With the stop pin of the rudder bracket facing upwards, start the bolts into the stern. Tighten the bolts securely using a 7/6 deep well socket, making sure the bracket stays flush against the stern and straight up and down. (illustrated in step - to the right) STEP : 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 0, 0,, 60/Excel): (Illustration -) Place the V-block rudder rest on the raised flat V-block mounting panel on the stern deck +/- forward of stern. Center the V- block 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 mm 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 T): Rudder rest is factory installed on all Pamlico T. 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 : 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. 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. Inspect the right (starboard) side of hull up along the deck. Depending on model, you will find: Pamlico 0, 0: Mark position on starboard side of deck approximately aft of, and slightly below Pamlico model name decal. Drill mm hole at mark. Pamlico, 60, Excel: Measure towards stern from Pamlico 60 logo and in line with logo. Drill mm hole at mark. Pamlico : Locate two pad eyes securing starboard side of stern deck bungee. Center round pad eye between and below bungee pad eyes. Drill mm hole at mark. Locate pad eye at forward end of uphaul line: Pamlico 0, 0: 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 mm bit. Pamlico, 60, 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 mounting holes. Drill each mounting hole with mm bit. Pamlico : Locate stern seat bolts on starboard side. Measure 0 forward of front bolt and down from crease defining cockpit coaming. Mark and center pad eye over mark, oriented with keel line. Mark mounting holes and drill each with mm bit.

3 Insert 8- x /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. 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 -) 6 Start 8- x /8 pan head screw through front mounting hole of pad eye and secure with lock nut. 7 Tighten both lock nuts securely. Step - 8 Return to hole drilled in step above between rudder and cockpit. Insert 8- x /8 pan head screw into center of round pad eye and insert into deck. Step - 9 Make sure uphaul lines are not tangled or crossed and align lines with cut outs in perimeter of round pad eye. 0 Secure round pad eye with lock nut and tighten. Make sure the rudder is stowed and centered. Slide the topmost turtle forward as much as possible. 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 -) Repeat process to remove the slack in the turtle in the lower up haul line. 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 - STEP : 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,, 60/Excel) also include extension system to allow rudder to be operated from stern or centered seat. Locate the rudder steering cable ports (the raised frogeyes on deck or side of hull.) Pamlico 0/0: on either side of deck, 0 / forward of stern. Pamlico : on either side of hull, 9 forward of stern. Pamlico : on either side of deck, 0 ¼ forward of stern Pamlico 60/Excel: on either side of deck, forward of stern. Step -7 Remove the rudder from the rudder bracket for ease of drilling access and set it aside.

4 REFER TO THE FOLLOWING PAGE FOR VISUAL INSTRUCTIONS Take great care in drilling! These steps are difficult to correct! Drill / 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 0o to o angle. Avoid drilling into angled forward face of frog eye. 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: Pamlico 0, 0: Remove existing footbrace assemblies and discard. Pamlico, 60/Excel: Remove the existing stern and central footbrace assemblies and discard. Pamlico : Locate indent (punch mark) in hull 8 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 mm hole at each mark. Insert # 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,, 60/Excel: Repeat for new center footbrace track. (Illustration - 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 0/0: 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 /8 cable clamp over the nylon tubing and place mounting hole over the exposed screw. Secure with original lock nut. (Illustration -7 on preceding page) Pamlico,, 60/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 /8 cable clamp over the nylon tubing and place mounting hole over the exposed screw. Secure with original lock nut. marine sealant to tube passing through bulkhead to eliminate possibility of leakage. 9 Pamlico 0, 0,, : Route tubing between side of seat and hull. Pamlico 60/Excel: Route the tubing forward and through the large hole in the seat. 0 Slide new pedal strap assembly onto stern and center (if applicable) rudder tracks. Align mounting hole of guide loop over mounting hole on stern end of rudder track Secure guide loop with # x /8 Phillips Trusshead screw. Slide stern footbrace all the way forward on the track. If necessary, adjust the length of the foot pedal strap via the tabler buckle. Pamlico 0/0: Cut the cable tubes shy of the ring of the foot pedal straps. Pamlico,, 60/Excel: Trim the tubing inches forward of hole in seat. 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. Feed into tubing through frog eyes and work forward until end extends beyond end of tubing. 6 Slide shrink wrap and ferrules over end of cable and push back against tubing. 7 Route cable through ring on pedal strap, extend beyond ring and align with balance of cable. Cut cable. 8 Slide both ferrules over cut end of cable and position about ½ apart. Firmly crimp both ferrules multiple times to firmly secure cable. 9 Slide shrink wrap over both ferrules and heat to shrink tightly over both. 0 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. 8 Pamlico 0, 0: If your boat is equipped with bulkhead, drill ¼ hole within 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

5 Important Instructions for using a tandem boat with rudder from solo paddling position. Pamlico,, 60/Excel. Slacken the foot pedal strap to allow access to screw securing guide loop Remove screw and guide loop from end of track.. Remove foot pedal by sliding off stern end of foot pedal track.. Unthread strap from tabler buckle at pedal assembly.. Install pedal on center track. Install guide loop on stern end of center track using existing hardware.. 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 FULLY ASSEMBLED HULL 6 9

6 TESTING THE RUDDER SYSTEM TESTING THE RUDDER SYSTEM STEP : SUPPORT THE BOAT BEFORE TESTING! 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. Remove the bungee cord securing rudder on the rear deck. Grasp the uphaul line at the turtles and test deployment and stowing of rudder. 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. With your legs equally extended, check to see that the rudder is in a neutral position, aligned with the centerline of the kayak. 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 60T Shown)

7 I I tem No. 70 N ET m l. PARTS LIST 7 H R E NON MFG. NC..007" Gap Fill High Strength Seals Refrigererants PART# 80-7

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