dukes4monny
regular
Reged: 04/02/2008
Posts: 134
Loc: Devon, England
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I helped a friend last year when a pontoon mooring line got under his Contessa 26 tiller in a blow and snapped it off. He took the remains to a local timber merchant, they cut a new piece to roughly the right shape. 2 hours fiddling and fettling by us with a power planer and sander, followed by two coats of varnish and the next morning we went sailing 
Well chuffed with the results too..........
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I came into this world with nothing..........so far I've managed to hang on to most of it
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SteveB_Sigma33
regular
Reged: 25/11/2003
Posts: 285
Loc: Port Solent, UK
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Do you know what type of wood you used?
I think it's going to be the cheapest and of course most rewarding way to go 
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plastic_dart
regular
Reged: 17/09/2006
Posts: 113
Loc: Gloucestershire
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I had a new tiller made up by Tony Mackillican. Excellent piece of work about £150 and made within 2 weeks. That was for a laminated shaped tiller which is a hefty size. Try e-mailing him, he gets back to you pretty quick and like I said he does a superb job at a reasonable cost.
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Carvel
regular
Reged: 12/11/2007
Posts: 139
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I broke a tiller a few years ago and found Robbins timber, Bristol very helpful. They recommended Oak or Ash, if I recall correctly, and cut me a suitable sized piece of Oak (very nice, slightly pinkish tinge to it, too) there and then for what seemed a reasonable sum.
I bought a spokeshave and spent a few happy hours copying the double curved shape of the broken one. That had been an old laminated one that de-laminated itself a bit when I fell on it in bouncy conditions on one of the first trips in my newly acquired boat ( a Hurley 22). Having copied the shape I then lovingly varnished it, and it looked a treat. Only after fitting it did I realise that it (and the tiller I had copied) were a bit too low for ideal comfort! Still, not bad enough to warrant changing, and it gave sterling service (and won approving comments) until I sold the boat.
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