So my Stump Grinding Lizard Blazer VL100 is getting the steering replaced for the fourth time. Teleflex NFB type helms have been the norm on this boat since I bought it. I'm tired of getting the slack developing in the helm over time and had a new BayStar Hydraulic Steering in the shop. This post is to address drilling your console to mount the replacement Hydraulic Helm Pump with a big hole already in the dash. BayStar & SeaStar need a 3in hole, centered, plus 4 - 5/16in diameter holes for the mounting studs.
Template.jpgHydraulic Helm and Drilling Fixture.jpgHole Saw Stabilizer.jpgHelm Fitted to Console.jpg
I used a piece of drop 1/8in 5052 Aluminum Sheet to make a drilling fixture with. First I lined up the top edge of the template paper with the top edge of the aluminum sheet. Then using a very sharp center punch I lightly punch a mark at the very center of each drilling designation. After moving the template out of the way I strike the marks well. Drilling the aluminum sheet on the drill press is straight forward but you do not cut the 3in hole in the template.
After your template pattern is drilled into the fixture you clamp the fixture to the console in the location needed. If you balance the new mounting holes within the existing holes the hydraulic helm will cover all old holes. A giant O-Ring works very well to seal the helm to the console front. You want it level with the floor of the boat generally. Drill your mounting holes while the fixture is well clamped.
So now your left with this large, undersized, hole in the center of your new mounting holes. This is no worries as you take your same drilling fixture and drill a scrap of wood with the same 5 hole pattern. After drilling, bolt the scrap of wood to your console bolt it securely on the console face. Once securely bolted the 3in hole in the center can be cut. Using the center hole drilled in the scrap of wood to locate the center for the hole saw you saw the 3in hole out. I come back and open the 4 stud holes to 5/16in as in the directions. Your helm should now fit perfectly.
BTW, I found a chart from Dometic that has force curves on it. BayStar steering with SeaStar hoses is only a 20% increase in force needed over a SeaStar system. If you use the BayStar tubing it is a 40% increase in force needed over a SeaStar steering system. It's worth buying the hoses if installing the BayStar on say a 70HP engine up.