Old Town Loon 160T Rudder(Before 2000) - Manual (Page 2)

6. At this point, you should decide which side you want to have the raising cord for the rudder
(usually on the opposite side of the paddle holder.) Drill a 3/16” hole 12” forward from the
rear seat bolt, of the seat tubing, and 1” up from the parting line. A cable clamp needs to be
placed on the deck for the raising cord bungee. This is accomplished by putting a cable
clamp on the rivet before it is placed in the drilled hole then place a flat washer on the
underside of the hull. Set the rivet using a pop rivet tool. (Illustrations #6)
7. Measure 60” back from the bow end and down 4” from the top edge of the kayak (the top
edge is where the top turns down to the side – DO NOT REFERANCE THE KAYAK
PART-LINE) Drill a 3/16” hole, install one end of the foot brace track by putting a large bolt
through the hull and securing it with a 5/8” lock nut. Now, working inside your kayak,
measures down 4” from the contour of the deck (this will be the same distance down as the
first hole you just drilled) hold your footbrace over your mark and drill out through the hull.
Slide you foot pedal on to the track and secure the track with a large bolt through the hull
and a lock nut. Measure to the middle of the track and drill another 3/16” hole out through
the hull – insert the 3/4" bolt and barrel nut to secure the middle of the track to the hull
8. With your black marker - mark the rudder cable 6” back from the bow end of the rudder
cable. Put two swages onto the rudder cable and slide the two swages to this mark – slip the
loop (on the foot pedal adjustment strap) onto the rudder cable. Loop the rudder cable back
around and slip the rudder cable back into the swages. Clamp the swages tight around the
cable with vice grips or pliers. (NOTE: Make sure the rudder cable does not stick out
beyond the end of the last swage.) (Illustration #7)
9. Attach the stern ends of the cables to the outer holes on the rudder. Place a stamped washer
on each 1” bolt (small) and drop them down through the holes on the rudder. Place a large
flat washer then the cable loop then another large flat washer onto the bolt and secure with a
locknut. (NOTE: Tighten the nut, being careful to leave enough room for the cable to move
freely.) (Illustration #8)
10. Tying the raising cords on the rudder. Fisherman’s Knot: A. Lay your two ropes side by
side, the ends pointing in different direction. You will need about 15” of free end on each
rope. B. Moving towards the second line’s free end, wrap the free end of the first line twice
around the standing part of the second so that the coils wrap around both ropes. Push the
free end through the center of the coils, leaving a 2–4 inch tail. C. Repeat by wrapping the
second line around the first in the opposite direction and on the other side, and then push the
free ends through the coils. Tighten the knot by pulling the standing ends of both ropes. You
can adjust the length of your raising cord by sliding the knots apart. (Illustration #9)
11. Stretch the rudder raising cord forward along the topside of the deck you mounted the cable
clamp to in step 7. Clip the hook end of the raising cord bungee to the raising cord, between
the two knots you just tied. Remove the cord lock from the end of the raising cord bungee
and slide the end of the raising cord bungee through the cable clamp on the topside of the
deck. After the raising cord bungee is through the cable clamp, replace the cord lock to keep
tension on the raising cord. (Illustration #6)
12. Rivet the jam cleat in line with the raising cord on the side deck. Position the jam cleat (in a
comfortable position about) 12” back from the rear seat track bolt along side the raising
cord. Use small flat washers on the underside of the rivet when mounting the jam cleat,
secure with a pop rivet tool. The sloped side of the jam cleat should be facing the stern of the
kayak so that when the cord is in the cleat, it can be pulled out in the forward direction but
will not slip out when there is tension from the stern. (Illustration #10)