Last year I reran all of my kayak steering cables on the Big Rig for the Torqeedo. Instead of swaging the cable termination at the foot brace I used a 3/16″ wire rope clamp. The original clamps made it through the season, but galvanized steel had rusted and corroded in no time.
The reason for this upgrade was to grant the ability of leaving the steering cables fully adjustable and removable for maintenance. A wire rope clamp is a U-bolt with a saddle and 2 nuts. A wire rope clamp is used for clamping down on 2 strands of wire rope to securely form a loop. They range in all different sizes. For this application a 3/16″ clamp is best. To assemble, insert the end of wire rope into clip saddle loop back around and set the end inside the saddle under the U-Bolt and tighten nuts until secure.
Previously using cable swages which permanently crimp to the cable and are only removed by cutting off. This made any sort of maintenance impossible without cutting the cable. Previously I was able to remove the swages using a Dremel tool precisely not to cut into the wire rope. This took time and was not ideal.
The new clamps pictured are stainless steel and should last much longer in the saltwater environment. The steel rope clamps are pretty inexpensive at around $1.50 to $2.00 apiece but can be purchased in bulk cheaper.
This particular install replaces the Jackson Factory installed Smart Track foot brace steering system. This article explains how to upgrade the steering on the Big Rig utilizing the Sea-lect Designs Toe Pilot foot braces. Using The Toe Pilot system you will simply angle the pedals like you would press a gas or brake pedal on a car to steer the rudder or electric motor. This eliminates the entire track sliding and one knee bent and one straight. Your entire day of fishing will be much more comfortable after this upgrade!
Illustrated in the video this upgrade is a semi advanced install but not an extremely difficult one. This upgrade will also work with the big rig stock Tru-Course rudder. This install conforms to the Torqeedo Ultralight 403 motor steering.
If your big rig does not have a steering kit factory installed Sea-lect Designs does manufacture a full Thru Hull Tru Course Rudder Kit which includes the toe pilot foot braces. The additional part if the install will be running the rudder cable tubing through the kayak.
#10 x 24 1 1/4″ Long Philips head bolt (Hardware Store)
#10 Washer (Hardware Store)
For Torqeedo Setup:
3/16″ Carabeners with eye
Install Instructions:
Removing Existing Smart track System Foot Braces Start with the front bolt. Using a 3/8″ socket with a 1/4″ drive and a Short Philips head screw drive remove the thru hull nut and bolt . Slide the foot brace forward to reveal the rear screw. Now remove the it with a Philips head screw driver. Slide off the back plate and now remove the cable from the foot brace using the 3/8″ socket. Cut the terminal connector from the end of the cable and remove the cable from the stern leaving the tubing in place.
Now you will need to remove the rivet that holds the cable tubing in place as it is int he area of where the new track will be installed. Using a drill bit drill out the center of the rivet until the flange falls off. The back portion of the rivet will fall inside the hull. Patch this hole using a plastic weld or Lexel caulk adhesive.Now using the #10 X 24 – 1 1/4″ bolt and #10 washer dab a drop of thread lock then fasten the left track to the right side of the kayak to the threaded insert. This will allow you to align the track and drill the new front hole. Once the hole is drilled using the #10 x 24 – 1″ bolt washer and nut fasten securely to the kayak. The tracks have to be installed upside down in order to reuse the threaded insert. If you would like to mount the tracks the intended way you will need a rigging bullet as it is impossible to reach the rear area of the track to fasten with a thru bolt.
Now once the track is installed repeat the same steps on the opposite side.
To run the cable.
Run the cable through the cable adjuster first then under the pedal is a hole run through the hole front to back then wrap it around in the groove then through the metal adjuster pulley at the top and then back to the rudder cable tubing which you will then run the cable through to the stern of the kayak. The cable wraps around the toe pilot like an ‘S’ pattern shape.
Once at the stern you will now connect the cable to your factory installed Tru-Course Rudder or in this cast to the Torqeedo steering bracket. Make sure the rudder or motor is centered at the same time the Toe Pilot pedal should be at 90 degrees to the kayak deck. This is to be center for both sides.
Now terminate the end at the cable adjuster by looping the cable through (2) swedges and crimping. Remove the tag end of cable using the diagonal wire cutters. Slide heat shrink tubing over and heat to protect the cut end and the swedges.
Refer to the image above for completed install.
Disclaimer:
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Last year I reran all of my kayak steering cables on the Big Rig for the Torqeedo. Instead of swaging the cable termination at the 
foot brace I used a 3/16″ wire rope clamp. The original clamps made it through the season, but galvanized steel had rusted and corroded in no time.
