My 505 DD2 autopilot upgrade

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   I agree with kipwrite: The angle of the rod could cause a problem. With my limited knowledges of physics I can imagine that there is a pulling up/pushing down force/movement on the rudder stock that could damage the bearings holdings. Keep in mind that the DD2 is three times stronger (375 KgM, DD1: 150 KgM).

Edited by tobo2 - 04 January 2021 at 10:52

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tobo2 Members Profile Send Private Message Find Members Posts Add to Buddy List Captain Joined: 14 February 2014 Location: Switzerland Status: Offline Points: 303	Post Options Post Reply Quote tobo2 Report Post Thanks(0) Quote Reply Posted: 04 January 2021 at 10:39
	I agree with kipwrite: The angle of the rod could cause a problem. With my limited knowledges of physics I can imagine that there is a pulling up/pushing down force/movement on the rudder stock that could damage the bearings holdings. Keep in mind that the DD2 is three times stronger (375 KgM, DD1: 150 KgM). Edited by tobo2 - 04 January 2021 at 10:52

ohthetrees Members Profile Send Private Message Find Members Posts Add to Buddy List Captain Joined: 24 November 2019 Status: Offline Points: 189	Post Options Post Reply Quote ohthetrees Report Post Thanks(0) Quote Reply Posted: 04 January 2021 at 10:48
	I’m not too concerned. Jefa made the bearings, rudder, and autopilot. This is also a solution engineered by Jefa, not something I did off the cuff. They sent drawings of the install, including this angle. I agree less angle would be better, and I’m going to ask them about my idea of a longer tiller arm pin.

tobo2 Members Profile Send Private Message Find Members Posts Add to Buddy List Captain Joined: 14 February 2014 Location: Switzerland Status: Offline Points: 303	Post Options Post Reply Quote tobo2 Report Post Thanks(0) Quote Reply Posted: 04 January 2021 at 11:00
	Good idea, send them your pics and your concerns. In fact only time can prove if it is a good solution. You are our oncomouse! Additionally the drive should be protected by a cover or so as you use the lazarette for storage (fenders etc.) that can block/damage the unit. Edited by tobo2 - 04 January 2021 at 11:02

ohthetrees Members Profile Send Private Message Find Members Posts Add to Buddy List Captain Joined: 24 November 2019 Status: Offline Points: 189	Post Options Post Reply Quote ohthetrees Report Post Thanks(0) Quote Reply Posted: 05 January 2021 at 21:30
	Sailed from San Diego to Ensenada. DD2 performed perfectly. A bit more gear noise than the DD1, but I still rate it a quiet autopilot overall.

ohthetrees Members Profile Send Private Message Find Members Posts Add to Buddy List Captain Joined: 24 November 2019 Status: Offline Points: 189	Post Options Post Reply Quote ohthetrees Report Post Thanks(0) Quote Reply Posted: 03 February 2021 at 23:50
	Still very happy with my upgrade. Now I'm in Banderas Bay, having come 1000 nm. Saw some decent sized following seas that had the autopilot working hard. DD2 working perfectly. I did have a bit of a tuning problem. For whatever reason, the calibration of my B&G H5000 autopilot computer that had been working fine with the DD1 was causing big over-corrections in all be settled weather. I even went through the Dockside then Sea Trial commisioning, and didn't help. I was starting to get worried because it just wasn't performing well when wind was powered up, or bigger following seas. But then I manually reduced the rudder gain, and suddenly it started performing brilliantly, and using a lot less power too. Summary: very happy to have an autopilot I trust!

Sailing Pilot Members Profile Send Private Message Find Members Posts Add to Buddy List Sub Lieutenant Joined: 24 August 2016 Location: Maine, USA Status: Offline Points: 6	Post Options Post Reply Quote Sailing Pilot Report Post Thanks(0) Quote Reply Posted: 06 May 2021 at 17:07
	I have a 2017 505 and sail from Maine to Bermuda to Puerto Rico and back every year. I just put the original rebuilt auto pilot back in after the replacement also started to act up (feeling rubbing at far ends of wheel movement with autopilot off, disconnect autopilot arm and it’s gone). I am thrilled with your replacement and will probably do this this summer in Maine. Do you have any more updates? And suggestions that you might do differently?Thank you so much!
	Carter

ohthetrees Members Profile Send Private Message Find Members Posts Add to Buddy List Captain Joined: 24 November 2019 Status: Offline Points: 189	Post Options Post Reply Quote ohthetrees Report Post Thanks(0) Quote Reply Posted: 22 August 2021 at 22:38
	Hi Sailing Pilot, Still happy with my upgrade. The only things I would add, you might ask Jefa for a slightly smaller reinforcing plate so you don’t have to cut yours down.

Sailing Pilot Members Profile Send Private Message Find Members Posts Add to Buddy List Sub Lieutenant Joined: 24 August 2016 Location: Maine, USA Status: Offline Points: 6	Post Options Post Reply Quote Sailing Pilot Report Post Thanks(0) Quote Reply Posted: 20 December 2022 at 17:46
	I am finally going to install the upgraded autopilot and Jefa is shipping it to me now. Any final lessons learned? Thank you so much for being the one to get this project working!
	Carter

ohthetrees Members Profile Send Private Message Find Members Posts Add to Buddy List Captain Joined: 24 November 2019 Status: Offline Points: 189	Post Options Post Reply Quote ohthetrees Report Post Thanks(0) Quote Reply Posted: 21 January 2023 at 19:18
	Still working great after some hard miles, though I'm working on getting a new pin machined that will reduce the angle between the arm and the tiller. I've 3D printed a mock-up so I know it will fit. Just need to find a place here in Colombia that can machine it for me out of 316.

ohthetrees Members Profile Send Private Message Find Members Posts Add to Buddy List Captain Joined: 24 November 2019 Status: Offline Points: 189	Post Options Post Reply Quote ohthetrees Report Post Thanks(0) Quote Reply Posted: 26 April 2023 at 18:53
	Thought I would give an update. The upgrade continues to be a very good decision, and I'm really glad I did this. Having confidence in the autopilot is critical. There is a clearance problem with the "stock" pins when the DD2 is installed in the 505. Their solution was to provide a taller drive arm pin, which made the angle problem worse. I felt the same could be accomplished by the normal drive pin, and a taller tiller pin, and that would improve the angle problem. I wasn't able to talk Jefa into agreeing that a taller tiller pin, and a shorter drive pin would give clearance AND a more direct push-pull. Language barrier? Not sure. Anyway, I designed a taller tiller pin and had it machined, replaced the drive pin with the shorter "stock" pin that comes with a standard DD1/DD2 kit (had one left over from my old DD1. The new setup looks great, doesn't interfere, and has a much more direct push/pull. The plastic bushings were damaged from the extreme angle, and the metal "rose joints" were dinged up from the pins and washers colliding with the metal at extreme angles. I removed the plastic ball from these expensive metal parts, and used a dremel to smooth (sandpapter wheel) then polish all the rough spots and now they are moving much more smoothly. The picture doesn't do justice to how much better the angle is throughout the entire range of motion. More details: I 3D modeled various pins and 3D printed them in plastic, just so I could mock up the clearance angles. PDF drawing of the tiller pin that you can show a machine shop: uploads/6425/Autopilot_Pin_Prototype_Drawing_v2.pdf Fusion 360 3D drawing: https://a360.co/41DONcf The shorter drive pin is available direct from Jefa. In fact it is the standard drive pin (I think butt not positive is part Z4-225 check yourself!), not the custom one that came with the Hanse 505 "upgrade kit". Below are some pics. As you can see the angle is much better. Edited by ohthetrees - 26 April 2023 at 18:55



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