Designing an aluminum Tiller
 

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.

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

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.

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

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