ULTIMATE 12 RUDDER INSTALLATION INSTRUCTIONS TOOLS NEEDED: DRILL ¼ DRILL BIT ¾ HOLE SAW 3/16 DRILL BIT PHILLIPS HEAD SCREWDRIVER 7/16 WRENCH HEAT SOURCE: PROPANE TORCH, LIGHTER OR HOT AIR GUN WIRE CUTTER CRIMPERS RIVET GUN 1. REMOVE THE SEAT AND FOOT PEGS. 2. REMOVE THE STERN FLOATATION FOAM. 3. CUT THE STERN GRAB HANDLE ROPE AND REMOVE FROM THE BOAT AND THE HANDLE. 4. USING A 3/16 DRILL BIT, CAREFULLY DRILL OUT THE 5 TH RIVET IN THE ADAPT A TRAC ON BOTH SIDES, COUNTING FROM THE STERN FORWARD. 5. USING A 3/16 DRILL BIT, CAREFULLY DRILL OUT THE 4 TH RIVET IN THE ADAPT A TRAC ON THE STARBOARD SIDE, COUNTING FROM THE STERN FORWARD. 6. USING A ¼ DRILL BIT, DRILL TWO HOLES IN THE STERN OF THE BOAT JUST ABOVE THE PARTING LINE FOR THE RUDDER UPHAUL LINES.
7. DRILL A ¼ HOLE ON THE PORT SIDE DECK, 3 FROM THE STERN. THEN DRILL ANOTHER 1/4 HOLE 1 FROM THE FIRST HOLE FOR THE RELOCATED GRAB HANDLE. 8. DRILL A ¼ HOLE 9 ½ FROM THE STERN FOR THE RUDDER HOLD DOWN BUNGEE. 9. PUSH THE BUNGEE DOWN THROUGH THE DECK OF THE BOAT. TIE A KNOT AT THE END OF THE BUNGEE.
10. USE A ¾ HOLE SAW TO DRILL THE HOLE FOR THE RUDDER UPHAUL LINES TO EXIT THE INSIDE OF THE BOAT RAIL. 11. DRILL A 3/16 HOLE 1 BEHIND THE SMALL BLACK PAD ON THE STARBOARD SIDE FOR THE UPHAUL BUNGEE. INSTALL THE BUNGEE WITH HOOK AND GATE USING AN 8-32 X ¾ SCREW AND NUT.
12. USE THE 3/16 BIT TO DRILL 2 HOLES ABOUT ¾ APART FOR THE GRAB HANDLE BUNGEE. NOTICE THE LOCATION IN THE PICTURE BELOW. 13. DRILL A ¼ HOLE THROUGH THE SIDE OF THE SEAT CLIPS ¾ DOWN FROM THE MOUNTING BOLTS. YOU MAY FIND IT EASIER TO DRILL THESE HOLE WITH THE BRACKETS REMOVED FROM THE BOAT. 14. PLACE A MARK 4 FROM THE STERN ON BOTH SIDES OF THE BOAT AT THE PARTING LINE. DRILL WITH A ¼ BIT. WITH THE DRILL STILL RUNNING, CAREFULLY LAY THE DRILL BACK TOWARD THE STERN IN LINE WITH THE PARTING LINE. THIS WILL ALLOW THE CABLES AND TUBING TO ENTER THE BOAT IN MORE OF A STRAIGHT LINE.
15. HOLD THE RUDDER BRACKET ON THE END OF THE BOAT WITH THE TRIANGLE END AT THE TOP. WITH THE BRACKET PUSHED TIGHT AGAINST THE STERN AND UP AGAINST THE RAIL, USE A MARKER TO MARK THE HOLE LOCATIONS. THIS MAY REQUIRE AN ASSISTANT TO MARK THE HOLES WHILE YOU HOLD THE BRACKET IN PLACE. 16. DRILL THE HOLE LOCATIONS WITH A ¼ DRILL BIT. 17. INSTALL THE BRACKET WITH THE SUPPLIED ¼-20 X 5/8 SCREWS AND NYLOK NUTS. 18. REMOVE THE 3/16 DIA. BUNGEE FROM THE STERN OF THE BOAT. INSTALL THE 12 BUNGEE IN ITS PLACE, TYING A KNOT ON EACH END.
19. PUSH THE ENDS OF THE SUPPLIED 20 ROPE UP THROUGH THE TWO NEW GRAB HANDLE HOLES YOU DRILLED IN STEP 7. PUSH THE ROPES THROUGH THE HANDLE AND TIE IN A KNOT. THE KNOT SHOULD PULL BACK DOWN INTO THE HANDLE. 20. PUSH THE ENDS OF THE SUPPLIED 30 BUNGEE INTO THE HOLES THAT YOU DRILLED IN STEP 11. PASS ONE LEG OF THE BUNGEE THROUGH THE HANDLE ROPE LOOP FROM THE UNDERSIDE OF THE DECK. THEN TIE THE TWO BUNGEE ENDS TOGETHER. THE BUNGEE SHOULD BE TIED TIGHT ENOUGH TO PULL THE HANDLE DOWN AGAINST THE DECK OF THE BOAT. 21. FLARE ONE END OF THE BLACK RUDDER TUBING WITH A HEAT SOURCE. FLARE THE END LARGE ENOUGH THAT IT WILL NOT PULL BACK THROUGH THE HOLES YOU DRILLED IN STEP 12.
22. PUSH THE TUBING INTO THE BOAT FROM THE STERN UNTIL THE FLARED END IS UP TIGHT AGAINST THE BOAT. 23. INSTALL A 1/4 P-CLIP ON THE TUBING AND INSTALL THE CLIP ON THE INSIDE OF THE BOAT ON THE BACKSIDE OF THE NEW 5 TH RIVET. 24. PUSH THE TUBING THROUGH THE HOLE YOU DRILLED IN THE SEAT CLIP. PULL TAUGHT. 25. CUT THE TUBING ABOUT ½ PAST THE SEAT CLIP. USE A HEAT SOURCE TO FLARE THE END OF THE TUBING LARGE ENOUGH THAT IT WILL NOT PULL BACK THROUGH THE CLIPS. 26. INSERT THE CABLES INTO THE BLACK TUBING FROM THE STERN OF THE BOAT. 27. REMOVE THE RUDDER PIN FROM THE RUDDER. INSTALL THE RUDDER ON THE BRACKET AND SECURE WITH THE PIN AND RETAINING RING.
28. PUSH THE RUDDER ROPES THROUGH THE TWO HOLES ON THE STERN OF THE BOAT THAT YOU DRILLED IN STEP 6. 29. INSERT A NEW RIVET INTO THE #4 LOCATION OF THE ADAPT A TRAC. INSTALL A 5/16 P- CLIP ON THE BACK OF THE RIVET. SET THE RIVET. 30. RUN THE ROPES THROUGH THE 5/16 P-CLIP. MAKE SURE THE ROPES ARE NOT TWISTED OR TANGLED. 31. PUSH THE ROPES THROUGH THE ¾ HOLE YOU DRILLED IN STEP 9. 32. ATTACH THE RUDDER CABLES TO THE RUDDER WITH THE CLEVIS PINS AND RETAINING RINGS. 33. ROTATE THE RUDDER BLADE SO THAT IT LIES ON THE DECK OF THE BOAT. SECURE WITH THE BUNGEE AND HOOK YOU INSTALLED IN STEP 9. 34. PULL THE RUDDER CABLES TAUGHT FROM THE SEAT AREA. CUT THE CABLES 13 FROM THE SEAT CLIP. 35. PUT ONE PIECE OF SHRINK TUBING AND TWO COPPER FERRULES ON EACH CABLE.
36. LOOP THE CABLE THROUGH THE GROMMET IN THE NEW FOOTPAD STRAP AND BACK THROUGH THE COPPER FERRULES. MAKE THE LOOP IN THE CABLE JUST BIG ENOUGH THAT IT WILL NOT BIND ON THE CORNERS OF THE WEBBING. THE CABLE SHOULD BE FLUSH WITH THE END OF THE COPPER FERRULES. 37. CRIMP THE FERRULES. USING A HEAT SOURCE, SHRINK THE TUBING DOWN ON TOP OF THE FERRULES. 38. INSERT THE NEW FOOTPADS ONTO THE FOOTRAILS. 39. USE A #8 SELF TAPPING SCREW INSERTED IN THE FRONT OF THE FOOTRAIL TO KEEP THE FOOTPAD FROM COMING OFF THE RAIL. 40. REMOVE THE HOOK FROM THE RUDDER BLADE. DETERMINE WHICH ROPE WILL ROTATE THE BLADE FROM THE DECK BY PULLING ON BOTH ROPES SEPARATLY. THE ROPE THAT MOVES THE RUDDER SHOULD PASS THROUGH THE HOOK. TIE THE TWO ROPES TOGETHER USING A BARRELL KNOT. 41. APPLY ADHESIVE ( LEXEL OR CONTACT CEMENT) TO THE TOP OF THE TRIANGULAR FLOATATION BLOCK. PUSH THE BLOCK INTO THE STERN OF THE BOAT. 42. APPLY ADHESIVE TO THE VISIBLE EDGE OF THE INSTALLED FLOATATION BLOCK. INSTALL THE BULKHEAD FLOATATION BLOCK TOP FIRST THEN PRESS AND HOLD THE BLOCK IN PLACE.