Converting a classic jet boat from mechanical linkages to a digital drive-by-wire helm: four control stations, closed-loop actuator control of steering nozzles and thrust deflectors, and servo-coupled engine throttle — built and refined across multiple phases with a repeat client. Watch the actuator prototype running below.
Classic jet boats are controlled through purely mechanical linkages — cables and levers connecting the helm to the steering nozzles and thrust deflectors. Our client is converting his vessel from analog to a full digital control system, and we've engineered that conversion across multiple project phases.
The system digitizes the helm: control levers are read electronically, and steering nozzles and port/starboard deflectors are positioned by actuators with closed-loop feedback — potentiometers on every nozzle and deflector confirm the real position, so the electronics know where the hardware actually is, not just where it was told to go. Control inputs run on a 0–255 scale with a 128 center point, remapped through calibration curves stored in EEPROM, and servo-driven engine throttle engages progressively beyond the deflector limits — direction and power on one control.
The video shows the actuator control prototype in bench testing before deployment. This is how we approach control systems for harsh environments: prove the behavior on the bench, calibrate it with the client in the real installation, and keep iterating — this client has come back to us repeatedly to extend the system.