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B I N S T R U C T I O N S

RUDDER KIT INSTRUCTIONS


TSUNAMI/CAPE LOOKOUT/CAPE HORN (POLYETHYLENE)

The addition of a rudder to a kayak results in additional control ADDITIONAL TOOLS & MATERIALS NEEDED
and efficiency, especially in certain sea and wind conditions.
Phillips Head Screwdriver Cable Cutters
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 talent.
Drill with 5/32” & 5mm Drill Bit 11/32” Wrench
CAUTION: All possible precautions have been taken to
provide for a successful installation of your new rudder but
Cigarette Lighter
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 Small Tube of Lexel, or
any part of this process, we suggest you contact your local (equivalent marine sealant)
dealer for support and advice. It is possible they will undertake
Deep 7/16” Socket
this installation for you at a modest cost.
Measuring Tape or Ruler
All directions included in these instructions reference starboard
(right), port (left), forward, stern, etc., are given as if you are
Crimpers
standing behind your kayak looking forward.
Inventory parts to confirm kit is complete before beginning
installation. A parts list with quantities is included at end
of these instructions. Note that as the kit is designed to Scissors
Rivet Gun
accommodate different boats, there will be parts that you may
not use.
Non-permanent marker
Call our Customer Service Line: 1(800)390-0819 should
additional assistance be required.
REVISION DATE
1.0 4/20/05
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 Step 2-1
into the rudder bracket, placing a small amount of Loctite®
adhesive on the bolt threads.
4
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 is 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 (Cape Lookouts and Cape Horns) Step 3-2


1
Place the V-block rudder rest on the raised flat V-block mounting
panel on the stern deck 11”+/- 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.
2
Using the holes on the sides of the block, mark and drill holes
using the 5mm drill bit.
3
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.
Installing the Bungee Rudder Tie Down (Tsunami)
1
Step 3
Thread provided bungee cord through the rear hole in the stern
most centered double pad eye and tie off with a secure knot (as
shown in illustration #2-1).
STEP 3: INSTALLING RUDDER UPHAUL LINE AND RUDDER
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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. (See step 3 to the right)
1
Unroll the up haul cord attached to the rudder. Place the rudder
in the rudder bracket and lay out the up haul cord along right
side of hull.

REVISION DATE
1.0 4/20/05
INSTALLING THE RUDDER
2
Inspect the right (starboard) side of hull up near the deck. Step 3-4 Uphaul line configurations by model
Depending on model, you will find:
Tsunami: Locate two circular insets. The first is 15” forward of
stern and the second is 39” forward on the 140 and 45” on the
145. Locate the indents for the pad eyes (Cape Horn will not
have indents) on the starboard (right) side of the hull (between
the cockpit and the stern). Drill a 5/32” hole centered in each
pad eye indent. (Illustration 3-2 on previous page)
Cape Horn: Mark position approximately 31 ½” forward of
stern and above scooped panel marking junction of deck and Step 4-3
hull. This position will be at stern corner of stern hatch. Make
sure that round pad eye does not overlap edge of hatch. Drill
5/32” hole at mark.
Cape Lookout: Locate inset in hull 6” aft, and 1 ½” outboard,
of stern most pad eye of deck rigging on starboard side. Drill
5/32” hole at mark.
3
Mount a round pad eye at each hole drilled in previous step.
Run the uphaul cord through the parallel guides in perimeter of
round pad eye, making sure that lines run parallel and untangled
from rudder assembly or previous pad eye. Insert 8/32” x ¾” pan
head screw through hole in center of pad eye and then through
the hull and secure with neoprene washer (neoprene against
hull) and nylon locknut.
4
The fitting securing the forward end of the uphaul line at the
cockpit will vary on different models. Precise location should
be personally determined depending on paddling position with
emphasis on easy and convenient access. Ideally, the uphaul line 5
There will likely be some slack in the uphaul line, more with
will run flat and straight from previous pad eye to final fitting. shorter kayaks. The uphaul line should be lightly tensioned
Slack in the uphaul line will be removed in following steps so so that it does not sag or droop between fittings. To adjust
don’t rely on existing tension to determine actual location. tension:
Tsunami/Cape Lookout: (Illustration # 4-4A) Once position a. Make sure the rudder is in the stowed and centered
is determined, drill 5/32” hole. Tie a loop in the shock cord position secured in the rudder rest.
assembly with hook, large enough to fit the loop onto base
of a round pad eye. Mount pad eye with 8-32 x 5/8” screw, b. Slide the top turtle line tensioner forward until it
secured with neoprene washer (neoprene against hull) and lock contacts the forward-most pad eye on uphaul line. Draw
nut. Clip hook onto uphaul line, making sure that one turtle the knot in the up haul line out of the “turtle” and pull
line tensioner is above and one below point where uphaul line is line taut without repositioning the turtle and tie another
clipped. knot against body of turtle. Remove remaining slack by
adjusting lower turtle in same fashion.
Cape Horn: (Illustration #4-4B) Once position is determined
(factory places pad eye just below the first “e” in Wilderness c. Release the rudder from the rest and test the up haul
logo), place a pad eye oriented parallel to keel line over mark line’s functionality by pulling the lower turtle forward and
and mark two mounting holes. Drill 5mm hole at each mounting then top turtle forward causing rudder to deploy and then
point. Install an 8-32 x 5/8” pan head screw through stern most raise to stowed position. There should be a slight amount
mounting hole, secured on inside of hull with a neoprene washer of tension in the line and the rudder should fully deploy
(neoprene side against hull) and nylon lock nut. Place end loop and fully stow on the deck. Pull the new knot out of the
of uphaul line through center hoop of pad eye and secure front turtle and cut the excess of the up haul line off just beyond
mounting hole with same hardware. Make sure one turtle line the knot. Slightly melt the knot with a lighter or match.
tensioner is above and one below pad eye. The knot will disappear into the fastener when released.

REVISION DATE
1.0 4/20/05
INSTALLING THE RUDDER
STEP 4: INSTALLING THE STEERING SYSTEM 7
The next step will be to secure the rudder tubing up under
The rudder steering system consists of a pair of cables running from the deck on the inside of the hull. Follow instructions below
the rudder up to and connecting with the foot pedals. The cables are for your specific model.
routed inside the hull of the kayak below the deck and on each side
of the seat. Tsunami: Locate the first half round pad eye on the deck
rigging forward of the rear oval hatch on each side. From
1
1. Locate the raised rudder steering cable ports (“frog eyes”) as inside of the hull, remove the nylon lock nut from the end
follows: of screw. Clip the ¼” cable clamp over the nylon tubing and
Tsunami: located just below junction of deck and hull place it over the exposed screw and use original nylon lock
approximately 4” forward of stern. nut to secure.

Cape Horn: on either side of deck, approximately 18” forward Cape Horn: Remove one lock nut securing pad eye on
of stern. either end of the forward strap of stern hatch. Clip the ¼”
cable clamp over the nylon tubing and place it over the
Cape Lookout: on either side of deck, approximately 18” exposed screw and use original nylon lock nut to secure.
forward of stern.
Cape Lookout: Remove one lock nut securing pad eye on
2
Remove the rudder from the rudder bracket for to allow access either end of the forward strap of stern hatch. Clip the ¼”
for proper drilling and set aside. cable clamp over the nylon tubing and place it over the
exposed screw and use original nylon lock nut to secure.
3
Take great care in drilling! These steps are difficult to correct!
8
Angling the drill bit slightly down towards the bottom of hull Drill a ¼” hole within 1” of top of any foam bulkheads
for those frog eyes on top of deck and slightly in towards center encountered. Run the tubing as straight as possible from
of hull for side mounted frog eyes, drill a 5/32” hole through the locations installed in previous step positioned so that each
flat stern face of each frogeye. You do not want to drill through tube runs between appropriate side of seat and hull.
the forward tapered face of the frog eye. Reinstall the rudder 9
assembly after these holes are drilled and install the split ring on Route the tubes between the seat and the hull forward to
the bottom of the rudder assembly post. (See Illustration 4-3 on the foot pedal area.
previous page) 10
Using the existing foot rail mounting holes, install the new
4
Remove the hatch covers and pockets to access the kayak footbrace tracks with the end with raised stop end towards
interior. the bow of the boat. The tracks will be secured with 1”
length Phillips Truss head screws inserted from outside of
5
Remove the existing foot brace assemblies and discard them. hull, going from the outside through the hull directly into
It may be necessary to reach inside via the hatches and the the track mounting holes.
forward storage compartment to remove these components on 11
older models as mounting screws were secured with washers Slide the new rudder pedal/strap assembly onto footbrace
and locknuts. On newer models, a self-tapping screw is used to tracks.
thread directly into the footbrace track. 12
Install the guide loop on the stern end of the footbrace tracks
6
On both sides, feed the straight (un-flared) end of the nylon using the 5/8” length Phillips truss head screw. Thread the
tubing forward through the newly drilled frogeye cable port. ring on end of the foot pedal strap through guide loop.
Reach through the stern hatch and pull the tubing forward
towards the cockpit.

10
11

19

12 13

FULLY
ASSEMBLED
14

HULL 14 18
5”

2”
REVISION DATE
1.0 4/20/05
INSTALLING THE RUDDER
13 4
Slide the pedal all the way forward on the track. If necessary, With the rudder deployed and the kayak safely supported, sit
adjust the length of the foot pedal strap via the tabler in kayak and place your feet on the rudder pedals. Pushing
buckle so that the pedal is in most forward position and the one pedal forward while relaxing pressure on the other
ring on opposite end of strap extends 2” beyond the guide makes the rudder pivot to the side pushed. Reversing the
loop on end of footbrace track. foot pressure makes the rudder swing to the other side.
14 5
Cut rudder cable tubes 5” shy of the ring on the foot pedal With your legs equally extended, check to see that the
strap. rudder is in a neutral position, aligned with the centerline
15
of the kayak.
Uncoil rudder cables. Remove pins and split rings from
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wings on each side of rudder head. Insert pin through eyelet Use extra caution with your new rudder
on end of each rudder cable and then through rudder wing. 7
Secure with split ring. Feed opposite end of cable into Be aware that the presence of a rudder requires new
tubing and push forward until end extends beyond end of precautions when launching and landing your kayak. Keep
tubing in cockpit area. the rudder stowed on deck with the bungee cord on rudder
rest released when launching or landing. Impact with the
16
Slide shrink wrap tube and 2 ferrules on each cable and bottom or other underwater may bend the rudder blades.
push all 3 fittings back on cable until shrink wrap contacts 8
tube. Use extra care to avoid personal injury when handling your
boat with a rudder installed. Be careful not to bump into
17
Route the cable through the ring and loop it back on itself your rudder when your boat is stored or on a roof rack and
so that 2” of cable passes beyond ring. Cut the cable at this when carrying kayak. Edges on the rudder are significantly
point. sharper than those on hull of your kayak.
18 9
Insert cut end of cable into each ferrule and position ferrules Test operation and familiarize yourself with rudder
½” apart. Firmly crimp each ferrule multiple times to secure performance in calm controlled conditions with assistance
cable. at hand. Test operation every time you launch your kayak
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and make any necessary adjustments before leaving shore.
Slide the shrink wrap over the ferrules and heat with a
10
lighter or matches to shrink and cover ferrules and raw end Secure rudder in deployed position with bungee cord before
of cable. lifting kayak onto vehicle as blade can scratch your vehicle.
20
Always have rudder blade secured when transporting your
Adjust the foot pedals to desired positions by releasing or kayak on a vehicle.
tightening strap at the tabler buckle. Use the same procedure
to tension the rudder cable to avoid unnecessary slack.
STEP 5: TESTING THE RUDDER SYSTEM

Support the boat before testing!


1
Situate the kayak so that it will safely bear your weight
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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 holding the rudder to the rear
deck. Grasp the uphaul line at the turtles and pull the lower
turtle forward and the upper turtle aft to make the rudder
blade swing down freely. Pull in reverse direction to raise the
rudder, noting the position of the turtle when the rudder is COMPLETED
stowed or deployed. It is recommended that you note the ASSEMBLY
relative position of each turtle corresponding to the rudder (Tsunami Shown)
position so that you can operate the rudder system by feel
and touch only. It is not unlikely that you will encounter
conditions where it can be hazardous to have to confirm
rudder position visually.
3
Check alignment and smoothness of operation.

REVISION DATE
1.0 4/20/05
PARTS LIST

Item No. 342701


NET 1 ml.
2N7
.007" Gap Fill
High Strength
4
HE
R
ON
G.
INC
. Seals Refrigererants
MF

PART# 3580-7229
REVISION DATE
1.0 4/20/05

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