Thread: Updating and Upgrading My Skeeter F-80 Strada

Like the Energizer Bunny work continues here. Swapping the Hydraulic Steering from my old Blazer VL100 to the Skeeter dealing with existing holes in the console prevented a accurate layout for mounting the Seastar Helm Pump. A pattern was needed to control the Holesaw from walking across the gelcoat as well as new mounting holes were needed very close to the edge of the existing center hole.



Using a piece of drop 3/16 aluminum sheet, a Dometic mounting pattern, some blue tape, and a center punch I first laid out where the new hole centers would be located on the aluminum.



I have the aluminum tightly clamped onto the drilling deck of my drill press. Aluminum cutting wax stick is used to lubricate the holesaw and slow speeds to reduce the chatter & sticking of the holesaw to the aluminum.



Now that the center 3in hole is cut I center a 5/16th bit on the stud mounting holes and drill those holes. Once that is done the aluminum is cut to square up the sides with the Helm so no matter how this new tool is used as long as one of the sides is level the Helm Pump will be level with the fill hole on top.



Now I'm left with a bunch of sharp edges & burrs. If I leave those and clamp the new template tool on to the gelcoat permanent damage will occur.



Using a "Surfacing Pad" on a air die grinder I polish every edge & burr smooth beveling the outer edges so no hard edge will come in contact with the gelcoat.



After centering the new center hole as best a possible allowing the same amount of stud mounting hole material all around I clamp the template tool to drill the first hole. As soon as the first hole is drilled I put a bolt securing the template then drill a opposing hole and bolt it. Now after that I can drill both the remaining holes. I used 3/16th thick aluminum so it would serve as a drilling guide for the holesaw & drill bit too.



The aluminum template is controlling the holesaw perfectly.



A bit of work in upfront fabrication but a template tool for perfectly fitting a Seastar helm to this Skeeter is fabricated. It will be useful as well for the numerous future Hydraulic Steering Installs that I will do. Makes the drilling a breeze.