Above deck sol'n - hydraulic drive
Possibly some ideas here that can help:
I have played with several AP solutions on my Olson 34. I am not happy with below deck installs as when something goes wrong at sea you find yourself alone in a very small space trying to solve the problem. Also, exposing a carbon rudder post and attaching a $500 added tiller arm seems to add to the possible failure mechanisms. I wanted the power and security of hydraulics, and the ability to use a redundant solution, at hand above deck. I also wanted to quick disconnect the cylinder completely from the tiller to eliminate drag.
My solution is shown in the attached photo. This is a hydraulic cylinder used in the power boat business mounted on an added box that is quickly removable from the deck via hard points I added to the transom cabinets, using stainless hardware, in a quick connect fashion. The tiller drops onto a pin mounted on the Teleflex cylinder drive plate. Installed in the tiller is a brass bearing sleeve to handle the load.
I usually don't leave this on board and attach when going out single handing. Install time is about 3 minutes. It uses the Type 1 pump as specified by many AP manuf. The cylinder was sized to match the reversing pump. The unit also contains the rudder reference unit, also home made, and therefore eliminating another worry, the below deck reference that is prone to failure.
I built an electronic interface to the drive motor so that any AP (B and G/RM/NKE) can be easily interfaced by simply attaching the drive signal from the AP to the interface. The interface is very robust, meaning the H drive is built with over-sized components to assure electronics don't burn out even if something silly happens, breakers go first.
I currently use an ST4000 soon to be replaced with the RM Tiller Pilot X5. The X5 control will drive my hydraulic unit or the native Tiller pilot. This gives me additional redundancy (two drive units) and the ability in a calm sea state, to operate at lower power (Tiller pilot). My ST2000 tiller pilot is still usable as well, giving me 3 pilots to choose from.
I have become a firm believer in hydraulic above deck drive. It is nearly immune to salt water intrusion as the only thing exposed to the sea spray is a cylinder full of hydraulic fluid. The failure modes of the typical above deck solution is gone, electronics that suffer from water intrusion and condensation. The drive is scary powerful. I once got leg between tiller and settee, I wasn't sure what component would fail first, tiller or leg.
The unit now has approx. 1000 single handing ocean miles under its belt.The pic., not great, has an ST4000 disconnected while doing work on the unit. Cost of this install was less than $500 total for the hydraulics, pump, home brew electronics ($25), connectors, home made container (birch ply + glass + liberal west system epoxy). Bulk of cost was the cylinder.
I could go on about the reliability about RM electronics in ocean passages, but won't start that here.
Brian
S/V Redsky SF Bay