As I stated in part 1 of this post, I opted to repair the tiller rather than simply buy a new one. The reason was two-fold; Obviously it’s less expensive to repair than replace and secondly, if I repair, I gain some bit of new knowledge.
I did a small bit of internet research and talked with a friend about repairing it and the consensus was to simply use epoxy to repair the broken tiller end.
I already had some 2-part epoxy. It was Gorilla brand with 3300 psi bond strength, so I figured that would be plenty strong enough.
I mixed up the epoxy, spread the split apart a little more than it was already and put the epoxy within the split. I put it as far down into the split as I could. I then clamped the tiller end shut with the C-clamps. If you’re wondering what the paint-stirrers are for, you’ll see in the next photo.
I let it sit for a couple days and it seems like a successful repair. The bolt holes are still unprotected, old and worn out, so my next step was to fill the bolt holes with epoxy. The idea is to re-drill the bolt holes and also reinforce the holes with some type of metal sleeve inside the hole.
I don’t have a full workshop full of all the necessary tools and equipment necessary to perform all tasks, so most times, I have to adapt and overcome [a term I learned and embraced while in the military.] So in order to re-drill the bolt holes, I used the tiller brackets clamped together to help align my drill so it’d be a more accurate hole. This method worked, for the most part, as I only missed one of the three holes by less than 1/16 of an inch. It was an easy fix to simply drill from the opposite side on that one hole to get everything aligned.
I took the tiller to the boat today and re-installed it. See below video for results.
Any ideas, thoughts or input on how I did this? Please comment.