After weeks of agonising work trying to get to the bottom of our steering system failure, we finally managed to drop the rudder in readiness for repairs and replacement parts. But, Jamie got called back to the UK, so everything went on hold.
Or did it?
Liz took the reins and managed to get a lot done in Jamie’s absence, including installing a new steering cable system. If any of you own an older boat with Whitlock steering, your cable probably runs through a plastic conduit, and if it is red, you should replace it.
What happens is that, over time, the cable will chafe through. It will also pick up dust, dirt and saltwater. All of these will contribute to steering system failure. So, if your boat has stiff steering and you know it is not your rudder, you may want to inspect your steering cable system now.
Replacing the old conduit is not straightforward as they are different diameters and require different end fittings. Of course, they’re different; it’s a boat, and boats like to make your life as difficult as possible. 🙄
Liz and Hendro (our Mr Mechanic with the can-do attitude) got on with removing the old cable and installing the new one.
It was a job Jamie had been dreading, and Liz still thinks he engineered a trip back to the UK just to get out of it!
Stiff Steering? It Might Be More Than Just Your Rudder
Every sailor knows the feeling of a responsive helm, where the boat answers with grace and precision. But what happens when a stiff, stubborn wheel replaces that smooth control? It’s a common problem that can make sailing a chore and, more importantly, can be a sign of a serious underlying issue. While many might first suspect a problem with the rudder itself, the culprit often lies hidden within the complex network of the steering system. This was exactly the case on SV Esper, where an investigation into stiff steering uncovered a series of worn-out components that required a complete overhaul.
Diagnosing the Problem: Beyond the Rudder
After hauling out, we identified lateral play in the rudder. The initial focus was on the rudder bearings. Upon dropping the rudder, we discovered significant wear where the stainless steel pintle (the pin at the bottom of the rudder stock) sits in its bronze cast heel on the skeg. Over years of use, the constant movement had worn the circular bronze hole into an oval shape, creating the unwanted movement and contributing to the stiff steering.
However, the rudder bearing was only part of the story. The primary cause of the stiffness was traced back to the steering cables and their conduits.
The Real Culprits: Worn Cables and Conduits
On many older boats with Whitlock steering systems, the cables run through a plastic conduit. Over time, this system is prone to degradation. Here’s what happens:
- Chafing and Friction: The constant back-and-forth movement of the steering cable eventually chafes through the inside of the plastic conduit.
- Contamination: Dust, dirt, and saltwater infiltrate the conduit, mixing with the grease to form a thick, abrasive paste.
- Increased Stiffness: This combination of a worn conduit and accumulated grime dramatically increases friction, making the steering feel heavy and stiff.
On SV Esper, the old red conduit had reached the end of its life. The advice from the experts at Whitlock Steering was clear: replace not only the steering cable but also the conduit.
The Fix: A Complete Overhaul
Addressing the problem required a multi-faceted approach, tackling both the rudder bearing and the steering cable system.
1. Repairing the Rudder Bearing
The worn, oval-shaped hole in the bronze heel needed a precise solution. Following the advice of sailing mechanic guru Viv Cox, the plan involved:
- Re-boring the bronze heel to create a perfectly round hole again.
- Machining a new bearing to fit inside the re-bored hole.
For this, Delrin®, the trade name for an acetal homopolymer, was the material of choice. This high-performance plastic is ideal for marine applications due to its low friction, high wear resistance, and minimal expansion when submerged in saltwater, making it a suitable replacement for metal-on-metal bearings that rely on water as a lubricant.
2. Replacing the Steering Cables and Conduits
With the rudder dropped, it was the perfect opportunity to tackle the entire steering cable run. This was no simple task. The old red conduit and cable had to be painstakingly removed from their path, which snaked from the steering pedestal in the cockpit, under the aft cabin bed, and back to the lazarette.
The old components were replaced with:
- A new, more durable blue conduit.
- Brand new stainless steel steering cables.
- Custom-machined end fittings and adapters from Whitlock Steering to accommodate the different diameters of the new conduit.
The installation was a complex job, requiring careful threading of the new system through the tight, inaccessible spaces within the boat.
Lesson Learned: A Stitch in Time
The story of SV Esper’s steering system is a valuable lesson for any boat owner. Stiff steering is not something to be ignored. While it may start as a minor annoyance, it’s a clear indicator of wear and tear that will only worsen. Regular inspection of your entire steering system—from the cables and conduits to the rudder pintles and bearings—is crucial for maintaining a safe and enjoyable vessel. Catching these issues early can prevent a small problem from turning into a major, and potentially dangerous, failure at sea.
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