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A long trolling motor shaft can be more of a hindrance than a help in certain fishing scenarios. Whether you’re navigating shallow waters, casting from a low-profile kayak, or simply tired of the control head towering over your bow, shortening the shaft of your Minn Kota trolling motor can be a practical and rewarding DIY project. This in-depth guide will walk you through the process, from determining the ideal length to making the final cut, ensuring you have the confidence and knowledge to customize your motor for optimal performance.
Before You Begin: Important Considerations and Warnings
Shortening your trolling motor shaft is not a one-size-fits-all procedure. It’s crucial to understand the implications and potential risks before you pick up a single tool.
Warranty Void: The most significant consideration is that cutting the shaft of your Minn Kota trolling motor yourself will void the manufacturer’s warranty. If your motor is still under warranty, it is highly recommended to have the shaft shortened by a Minn Kota Authorized Service Center. This will ensure the work is done professionally and your warranty remains intact.
Model Restrictions: Not all Minn Kota motors are created equal when it comes to shaft modification.
- Models That SHOULD NOT Be Shortened: Trolling motors with automatic stow and deploy features, such as the Ulterra, Ulterra Quest, and Riptide Instinct Quest, have complex internal mechanisms that are calibrated to a specific shaft length. Attempting to shorten these shafts can lead to catastrophic failure of the stow/deploy and trim functions.
- Models That Are Difficult to Shorten: Foot-controlled models like the Maxxum and Fortrex present a significant challenge. The top of the shaft on these motors has a recessed area where the steering pinion sits. Cutting the shaft removes this recess, and recreating it with precision is extremely difficult without specialized equipment. An improperly seated pinion will result in erratic and unreliable steering. While it’s not impossible for a professional, it is not recommended as a DIY project.
- Ideal Candidates for Shortening: Hand-controlled models such as the Endura and Riptide Transom, and electric-steer models like the PowerDrive and Terrova, are the most suitable candidates for this project. Their simpler head and steering mechanisms make the process more straightforward for the average DIYer.
Safety First: This project involves working with electrical components and cutting tools. Always disconnect the trolling motor from its power source before beginning any work. Wear appropriate safety gear, including safety glasses and gloves.
Why Shorten Your Trolling Motor Shaft?
There are several practical reasons to undertake this modification:
- Improved Casting Clearance: A shorter shaft lowers the control head, providing more room for casting without obstruction, especially on boats with lower gunnels.
- Enhanced Kayak and Small Boat Usability: For kayak anglers and those with smaller jon boats, a long shaft can be cumbersome and position the control head at an awkward, uncomfortable height.
- Reduced Prop Depth in Shallow Water: In skinny water, a long shaft can force the propeller too deep, causing it to drag in the mud and spook fish. A shorter shaft allows for a more appropriate prop depth.
- Easier Stowing: A shorter shaft can make the stowing process more manageable and result in a more compact and secure fit on the boat’s bow.
Determining Your Ideal Shaft Length
Before you make the cut, it’s essential to determine the correct new length for your shaft. The general rule of thumb is that the center of the motor’s lower unit should be at least 12 inches below the waterline for optimal performance and to prevent cavitation (the prop sucking in air).
- Position Your Boat: With your boat in the water and loaded with your typical fishing gear and passengers, position the trolling motor as you normally would.
- Measure the Waterline: Measure the distance from the top of the bow where the motor is mounted down to the waterline.
- Calculate the Ideal Depth: Add approximately 12 to 18 inches to your measurement from step 2. This will give you a good starting point for your new shaft length, ensuring the prop stays submerged in most conditions. For those who frequently fish in rough water, adding a few extra inches can provide a buffer.
- Mark Your Cut: Once you’ve determined the desired length, use a pencil or marker to clearly mark the cutting point on the shaft. Remember the adage: measure twice, cut once.
Tools and Materials You’ll Need
Gathering the right tools and materials is crucial for a smooth and successful project.
Tools:
- Safety Glasses and Gloves
- Screwdriver Set (Phillips and flathead)
- Wrenches or Socket Set
- Hacksaw with a fine-tooth blade or a Tubing Cutter: A tubing cutter will provide a cleaner, more precise cut on the composite shaft.
- Power Drill and Drill Bits: A sharp drill bit is essential for creating a clean new mounting hole.
- Wire Cutters and Strippers
- Butt Connectors and a Crimping Tool
- Heat Gun and Heat Shrink Tubing
- Center Punch (optional but recommended)
- Round File or Deburring Tool
- Caulking Gun
Materials:
- Marine-Grade Sealant: A high-quality, waterproof sealant is non-negotiable. Products like 3M 5200 Marine Adhesive Sealant or a specialized trolling motor shaft thread-locking sealant are excellent choices.
- Dielectric Grease: To protect electrical connections from corrosion.
Step-by-Step Guide to Shortening Your Minn Kota Shaft
This guide will focus on the more straightforward process for hand-controlled and electric-steer models like the Endura, PowerDrive, and Terrova.
Step 1: Disassembly
- Disconnect Power: Completely disconnect the trolling motor from the battery.
- Remove the Control Head:
- For hand-controlled models, there is typically a single through-bolt or a set of screws holding the tiller handle/head to the top of the shaft. Remove these fasteners.
- For electric-steer models (PowerDrive/Terrova), you’ll need to remove the top cover of the control head. This usually involves removing several screws. Be mindful of any indicator lights or buttons and their wiring.
- Expose the Wiring: Carefully lift the control head or tiller handle off the shaft. You will see the main power wires (and potentially other sensor wires for i-Pilot models) running down the inside of the composite shaft.
- Document the Wiring: Before disconnecting anything, take clear photos of the wiring connections inside the head. This will be an invaluable reference during reassembly. Note the colors and their corresponding terminals.
Step 2: Cutting the Shaft
- Secure the Shaft: Securely clamp the trolling motor shaft in a vise or on a stable workbench. Use a soft cloth or rubber jaw protectors to avoid scratching the composite material.
- Protect the Wires: Gently pull the wires up and out of the top of the shaft as far as they will go to create slack. This is the most critical step to avoid damaging the internal wiring during the cut.
- Make the Cut:
- Using a Tubing Cutter (for metal shafts): Place the tubing cutter on your marked line and slowly and steadily rotate it around the shaft, gradually tightening the cutting wheel with each rotation. This will produce a clean, square cut.
- Using a Hacksaw (for composite shafts): If using a hacksaw, wrap the cutting line with masking tape to help prevent splintering of the composite material. Use a fine-toothed blade and make slow, controlled strokes to ensure a straight cut.
- Deburr the Edge: Once the cut is complete, use a round file or a deburring tool to smooth the inside and outside edges of the newly cut shaft. This will prevent any sharp edges from chafing the wires.
Step 3: Drilling the New Mounting Hole
- Mark the Hole: Carefully measure the location of the original mounting hole on the piece of shaft you just cut off. Transfer this measurement to the newly shortened shaft. Use a center punch to create a small indentation to guide the drill bit and prevent it from “walking.”
- Protect the Wires (Again): Push the wires down into the shaft, far away from where you will be drilling.
- Drill the Hole: Using a sharp drill bit of the correct diameter, drill the new mounting hole through the shaft. Drill slowly and steadily to ensure a clean hole.
Step 4: Shortening and Reconnecting the Wires
- Calculate Wire Length: You will now have an excess length of wire. You need to shorten the wires to prevent them from kinking or getting pinched inside the smaller space of the control head. The amount of wire to remove should correspond to the length of the shaft you cut off.
- Cut and Strip the Wires: Carefully cut the wires to the appropriate length. Strip about half an inch of insulation from the ends of the wires.
- Reconnect the Wires:
- Using appropriately sized butt connectors, crimp the wires back together, ensuring you match the colors correctly based on the photos you took earlier.
- Slide a piece of heat shrink tubing over each connection before crimping the other side.
- Once the connections are crimped, use a heat gun to shrink the tubing, creating a secure and waterproof seal.
- Apply a small amount of dielectric grease to the connections for an extra layer of corrosion protection.
Step 5: Reassembly and Sealing
- Feed the Wires: Carefully feed the shortened and reconnected wires back down into the shaft.
- Apply Sealant: Apply a generous bead of your marine-grade sealant around the top edge of the composite shaft where the control head will sit. This is crucial for preventing water intrusion down the shaft, which can damage the motor’s electronics.
- Reinstall the Control Head: Slide the control head back onto the shaft, aligning the mounting hole. Ensure the head is properly seated in the sealant.
- Secure the Head: Reinstall the through-bolt or screws that hold the head in place. Do not overtighten, as this can crack the composite shaft or the control head.
- Final Sealing: Wipe away any excess sealant for a clean finish. It’s also a good practice to apply a small amount of sealant around the head of the mounting bolt or screws for added water protection.
- Cure Time: Allow the sealant to cure completely according to the manufacturer’s instructions before using the trolling motor. This can take anywhere from 24 hours to several days.
A Job Well Done
By following these detailed steps and taking the necessary precautions, you can successfully shorten the shaft of your Minn Kota trolling motor, customizing it to your specific needs and improving your overall fishing experience. While the process may seem daunting at first, with careful planning and execution, you’ll be back on the water with a more efficient and user-friendly trolling motor in no time.