Designing an aluminum Tiller

[Stumble]

My wood laminate tiller recently cracked on my racing sailboat. I was about to buy a new one, when I picked the thing up and realized that it weighs about 5 lbs. Now I know that I am just a tad weight sensitive on this boat, but I just can't seem to justify carrying that much weight for a tiller.

I was thinking instead of fabricating an aluminium tiller from 2x1 rectangular tubing (the right size for the tiller bracket) with a handle attached at the end. This should reduce the weight by about 3.5 lbs, and I would think that it would be at least as strong or stronger than the original. I had also thought about then drilling out 1" holes from the top and bottom of the tiller to further reduce weight.

However before I go this route, I was wondering if anyone can see a flaw in the design, or have a reason why it is a bad idea. I could very easily just be overlooking some basic problem, and would certainly prefer to know that before going through the hassel of makeing it.

[Brian Duff]

what boat? Which way is the 2x1 dimension arranged plan view wide and short height?

[Stumble]

Sorry about that... It is on an Olson 30, with a fully stock rig and rudder. My idea was to have the one inch side vertical with the 2 inch side horrizontally. So as you looked down you would see the wide side of the bar.

[Ian McColgin]

But won't the air resistance and turbulence from all those holes more than off-set what marginal weight saving you might gain?

In other words, let's not over-engineer the job.

G'luck

[Brian Duff]

na dude - lightening holes are lightening fast. low weight is where its at. gotta keep the pounds off.

every ounce counts.

and we can weld a cap on each end and use it as a rum keg too, which will save the weight of the bottle.

plus it can serve as a spare compression post so that wont be needed either - less weight still.

oh and it would make a fine reaching strut to be sure


but your best bet would be to just buy another wooden tiller from west marine and go sailing