G'day LLoyd.

The hinged rudder pedals I am referring to are not the sealine system included in the link below. They may be OK, but they do not appear to offer the full footbrace that I like.

The type I was referring to are shown at http://www.mirageseakayaks.com.au/features.html

My attempt at a similar systen is shown at http://community.webshots.com/photo/100919710/177124680UDPbXF

To fabricate it is best done while the kayak is under construction (ie, with no deck):
1. Work out the adjustment range needed - closest and furtherest from the seat.
2. Work out how far up from the keel the footbrace needs to be for comfort. I did steps 1 and 2 by trial and error, using a piece of strip duct-taped across the hull.
3. Measure the minimum distance across the hull at the correct height for the footbrace. Usually this will be at the point of adjustment furthest from the seat. Deduct say 60mm than this measurement to give you the distance between the two sets of holes in the mounting plates that will be glued to the inside of the hull.
4. Make up a fitting jig which is simply a piece of 6mm plywood with holes drilled at the "corners" of the rectangle which is "adjustment range from step 1" long and "hole separation from step 3" wide.
5. Make up the mounting plates from 6mm ply. When viewed from above they will have to taper towards the bow to conform with the inside of the hull over the adjustment range. Do not worry about drilling the ranks of holes in each plate at this stage.
6. attach the plates to the fitting jig with bolts. Lay the assemblage in the hull and level it. do the fianl fitting of the mounting plates to the hull. The jig holds the plates square to each other and firm against the hull on both sides.
7. Epoxy the plates to the hull. When dry remove fitting jig and then reinforce the entire surface of each plate and all joins with fibreglass.
8. Make up a footbrace using two pieces of timber. The hyper-dedicated could strip build one. The angle betwwn the horizontal piece (which bolt to the mounting plates eventually) and the "vertical" piece against which your feet will rest is somwehere between 110 and 130 degrees. Work it out for you in your seat in the hull. Drill two sets of 10mm holes on each side of the howizontal part of the footbrace at the "hole separation from step 3" distance.
9. Use the holes in the footbrace as guides to drill the ranks of 10mm adjustment holes in the mounting plates. Fill all holes in footbrace and mounting plates with epoxy and redrill with 6.5mm drill using footbrace as guide to ensure all holes line up.
10. Glue 4 stainless steel bolts into holes in footbrace.
11. Make up and fit rudder pedals to footbrace with stainless hinges. Drill-fill-drill hole in top outside corner of each pedal for rudder control cables.
12. Drop footbrace into appropriate place on mounting plates, bolt down with stainless wingnuts.
13. Consume beverage of choice while contemplating masterpiece. Assuming timber, 'glass and epoxy is surplus from main building project, total cost is time plus 4 nuts and bolts, two hinges and screws for the hinges, (all stainless).

Finished product is solid as a rock, relatively light weight and comfortable, as your feet are solidly supported yet can be located in many positions.

Cheers, Tony Bligh