I've just run into a big problem in trying to fit a tiller arm on the rudder
shaft to support a hydraulic autopilot ram. The existing keyway in the
rudder shaft is only about 3.5 inches long - about enough to accomodate the
quadrant with an inch or so of excess. I have been attempting to get the
keyway extended a few inches to allow an autopilot tiller to be added to the
shaft.

The rudder is out and has been taken to a marine machine shop specializing
in shafts. They are unable to lengthen the keyway due to the rudder blade
preventing them from being able to set up the cutting machine (a
Bridgeport). Other machine shops have also been unable to do the job.

Has anyone out there had this type of work done and if so did you have
similar problems - or know of a machine type that is capable of doing the
job? Otherwise what other means of securing the tiller arm are you aware
of? I've thought about trying to use the remnant key - although it is
pretty short - or drilling the arm and shaft to allow a pin to secure the
arm. Any experience or thoughts?

Maybe I should just get a windvane and drive it with a small tiller pilot -
sure would like to use the hydraulic a.p. though since I already have it.

-- 
Mark Bergin
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