Building a new tiller

The tiller on Salammbo was looking pretty decrepit and it was time for either a refinish or a rebuild. Since the tiller had already been fixed at least once in the past, and wasn't looking great, I decided to go new. I also had some nice 1 1/4" thick white ash available from a paddle making project my Scout group did a few years back that I knew would look great as a tiller handle. White ash is strong and durable. 

• The first step was to simply trace my old rudder onto the stock. I liked the existing rudder feel so have no need to change the shape. 

Tracing the tiller

• Cut out the rough shape with a jig saw. 

Rough cut tiller

• I used an aggressive rasp to remove the bulk of the material. A less aggressive file tuned up the shape.

Rasp shaped tiller

• I used a power sander with 60 grit paper to smooth out the rasp marks and followed that up with 120 grit and then 220 grit.

• I finished the tiller with 6 coats of Epifanes Clear Varnish

Finished tiller