Rotary Rudder Steering System for Kayaks

This rudder steering system is designed as a DIY rotary-style controller for stern-mounted rudders on fishing kayaks, specifically tested with the Ascend 133X. The design is inspired by the Tim Percy Universal Steering concept, but fully custom-modeled and 3D printed using ASA filament for outdoor durability.

The system uses a rotary dial controller mounted to the left-side tackle tray, connected via sleeved stainless steel cables that route to a rudder in the rear. The control cable wraps around the rotary dial, travels through two cable sleeves along the kayak's exterior, and connects to the rudder via sleeve stops.

🛠️ Build Details:

• Rotary Dial Assembly: 3-part build (lever, spacer, and rotary disc) mounted to a baseplate with PTFE washers and a central M6 shoulder bolt
• Cable Routing:
  • Cable Housing: 5mm black PVC brake cable housing
  • Cable: 1.5mm (1/16”) 304 stainless steel wire
  • Stops: Crimp-style aluminum cable stops + metal end ferrules
• Rudder: Amazon universal kayak rudder (linked here) with extended post and built-in rope return system for stow/deploy

🧵 Installation:

• The rotary system mounts via T-track with a ball-joint bracket for quick repositioning or removal.
• Cable housing is anchored at each end with custom mounts and secured inside the rotary dial using grub screws.
• A weep-hole or chamfered escape was added to allow any water drainage inside the housing.

This system allows for one-handed, analog-style steering while keeping your feet free for fishing or paddling. Built under the CopOnPC project series.