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post #1 of 9 Old 01-16-2008 Thread Starter
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Autohelm 4000

Hi, I'm trying to locate a clutch lever (part#A18057) for my Autohelm 4000. So far I have been unsuccessful. I contacted Raymarine and it is no longer stocked. I've been searching with google and still no success. Any suggestions on where to look???? This unit works great and I would hate to have to get rid of it over this little part.
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post #2 of 9 Old 01-16-2008
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I have the same unit and I'm familar with the handle in question.
No need to toss the unit, it's a simple plastic lever, make one out of wood (with a set screw to tighten it on) or have a local machinist fabricate one out of aluminum or brass.
Or, find something close at home depot (a faucet handle for instance) break out a file and shape as needed.
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post #3 of 9 Old 01-16-2008
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In case you decide to go with fabrication; I found this on the hunter owner site (he's making it out of 3/8 aluminum plate stock):

The shaft dimensions are (inches): .119 from the flat to the other side and .159 across the diameter.
I traced the outside shape of the handle and marked the location of the hole and the flat at the same time.
Then I drilled a #32 (.116) hole for the shaft.
With a jewel’s file I put a flat (just eyeballed the width of the flat) in the correct location.
Then just to make sure it would work (before cutting the whole thing out); I cut a slot in from the edge parallel to the flat to the center of the circle and about .25 inch on the other side of the hole. Then tried it on the shaft and it fit (tight).
Just by filing the flat and cutting the slot the hole diameter opened up to fit the .159 shaft.
Happy with the fit, I cut the outside shape, drilled and tapped a 4-40 screw hole perpendicular to the slot to pinch the hole closed, filed all the edges and buffed it up a bit.
Just a note: you need to drill out one side of the 4-40 tapped hole to the clearance size so the screw only threads into half of the clamp.

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Aluminum is soft enough to do this with hand tools, as is brass.
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post #4 of 9 Old 01-16-2008 Thread Starter
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Thanks, I am going to try fabricating.
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post #5 of 9 Old 01-16-2008
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Yeah, it's winter, what else you got going on that's near as much fun - and if you do it in brass and shine 'er up you can always point at it and thump your chest like a mighty male who has conquered the act of self repair at sea.

I'm off to fix my radio, wonder where I left those coconuts and the string....
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post #6 of 9 Old 01-17-2008
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You may start watching ebay and see if you can come up with a damaged or non working unit that someone is selling as scrap then salvage the needed parts.

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post #7 of 9 Old 01-17-2008
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I see this post is almost a couple of years old. However, I have an old 4000 wheel pilot that I just replaced with a new mkII.l if someone needs parts let me know...

Ron Hall
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post #8 of 9 Old 01-18-2008
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Ron, this is a new thread, it was started 1 day ago, hopefully Gulfislander will see your post.

I have a 4000 also, but all is well so far

1955 Blanchard 51 Custom ( I got a woody )

1974 Ranger 33


Lord, give me coffee to change the things I can change and Rum to accept the things I can't
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post #9 of 9 Old 01-19-2008
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Gulfislander replied to me via private message but I was unable to answer him because I do not have enough posts to respond to private messages. ( I think I need ten posts before I can reply) Anyway, my wife put the old 4000 autopilot in the trash last week. Sorry....

Ron Hall
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