Shelter Island Boat Works

While out sailing the tiller broke. It seems my crack boat yard was not bedding the screw attachments for the tiller handle when they removed it for varnishing. Thus, it rotted! So, I had to build a new one. I temporarily lashed it back together to get home.

The old one was a solid piece of steam bent white oak. The extension handle was mortised in to the end of it. The first step was to make a mold of the curvature of the old tiller, then I decided to laminate 1/4″ strips of white oak. This would make it stronger and more stable than just using a solid piece.

After laminating it in the mold I trimmed it down to match the original. Then laid it out to accommodate the rudder head fitting attachment. Next up was mortising the end to receive the handle fitting. Then, of course, I bedded the screw attachments!

After ten coats of varnish I installed it on the boat. Looks exactly like the old one, just stronger. Came out well. No worries for quite a while now!