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

Atomic 4 rebuild - Head removal

Atomic 4 head - bolts out

 As a non-mechanic, removing the Atomic 4 head had a very high nifty-factor. This is my first glimpse into the belly of the beast!

Removal of the head was somewhat difficult. There may be a better way to do it than mine!

I attempted to remove the remaining twelve nuts holding on the head. Only about half of the nuts came off easily. The other half brought the studs (threaded on both sides) with them because they were seized on.

Atomic 4 head - Half off

My plan, once I have more stripped off, is to take the block to an engine mechanic for some general advice on whether to extract those remaining pins and how to generally proceed.


The head was difficult to remove because of the remaining pins. I had to pry around the edge with a large screwdriver (trying not to damage the head surface) and then I used a wooden block placed under the thermostat housing to beat the head upwards. As I said, there is probably a better way to do this!

Atomic 4 - Headless

There are two gaskets, both of which were destroyed in the removal. I had planned on replacing them anyways though.

Since the engine is seized, from many years of not being used, I took the opportunity to thoroughly soak the top of the pistons with WD40 to try to get things moving again.

Atomic 4 head - off

[All of the posts associated with this rebuild are available under the search label Atomic 4 Rebuild.]

Atomic 4 Rebuild - Transmission cover and housing - Part 1

Transmission - Pre-dissasembly

Removing the transmission cover and housing was a bit of a challenge...and continues to be.  I also don't think that I did it correctly. Hopefully I didn't cause myself grief down the road when I try to put things back together.

I removed the four 3/4" bolts (1/2") holding the transmission cover, exposing the transmission.

Cover plate removed

I the removed the thrust bearing (the round plate at the back of the transmission). This is held on my six 1" long bolts (1/2").

Rear of transmission before removal

I have since discovered that I should have first removed the tail shaft nut first.

Removing the transmission housing was difficult, as it was securely stuck by gasket goop and decades of rust.

I first removed the ten bolts holding it in place. These include four 1 7/8" (1/2"), two 2 5/8" (1/2"), and six 3/4" (1/2").

I was apprehensive about beating too hard on any particular piece because I wasn't sure how solid they were. In the end I used a knife, large screw driver and hammer to poke, pry and beat the housing until it dislodged. No damage done. (except the gasket)

Removing that nut is now much more difficult (I haven't actually figured out how to do that yet) since the nut spins on the bearing (surprise surprise).

I thought it would be easier to find something to pry on once I removed the whole housing and transmission. Not so much...

Housing and transmission removed together

Here is the finished product.

Atomic 4 without transmission

[All of the posts associated with this rebuild are available under the search label Atomic 4 Rebuild.]