Make a Simple Rudder & Tiller Arm

Making a rudder assembly and tiller arm is quite simple providing you have a few basic tools plus a soldering iron rated at about 40 watts or more.   Also, you will need some materials: a small piece of 1 or 1.5mm thick brass sheet, a short length of 2.5mm brass rod, a short piece of brass tube which is a snug fit over the brass rod, a brass collett with a 2.5mm hole and a short piece of 6mm x 2mm brass.

Now you can cut the parts as required.  My diagram shows a very simple rudder shape but you can cut it to any shape as required.

If you are working from a plan then just transfer the measurements from this to your materials.  When cutting the brass rod which attaches to the rudder blade (see diagram above) make sure you leave sufficient length to get it above the waterline and leave enough to fasten the tiller arm to.

Next you need to cut a slot about 12mm long down the centre of the brass rod.  This is to allow the rudder blade to slot in (see diagram above).  To cut this slot use a junior hacksaw or a cutting disc if you own a dremel or something similar.  Remember to clamp it firmly in a vice and wear goggles.  Finally, you need to solder the rudder shaft (brass rod) to the rudder blade.  Ideally this is best silver soldered but I have made many of these using soft solder and to date none of these have ever broke on me.  As it is easier to soft solder this is the method I would recommend for small rudders.  If you have not done much soldering click here for some tips.

Now you are ready to make the tiller arm assembly.
First cut a piece of the brass bar to a length of 40 - 50mm.  This length can be altered to suit your requirements.  Round off the corners and then drill a number of holes for the servo push rod (see diagram).  Next solder the arm to the brass collett. Finally, using a 

drill the same size as the hole in the collett, drill through the arm so the shaft can pass through both of them and be secured by the grub screw.

You are now ready to fit the rudder/tiller arm assembly to your hull. Mark the position for the rudder on the hull and drill a pilot hole.  Epoxy a small block of wood to the inside of the hull directly above the pilot hole.  Drill through the hull and block of wood using a drill the same diameter as the brass tube.  Push the brass tube through the hull leaving about 5mm protruding below the hull. Fasten in using epoxy.  Finally, push the rudder assembly up through the tube and fit the tiller arm.  Adjust the height etc. as required.  (See diagram).