Foss Foam used to be (3 years ago?) in Florida
. They may be the only "rudder builders" in the US...but I'd look for another source. I know someone who lost
several months while they screwed around, made a rudder that didn't fit (their mistake) and took forever about correcting the problem. And the finished product never quite balanced like the original did, "close" wasn't good enough.
That was also a "gee, it leaks
a little" problem. Henry, if there's any water in the rudder at all, it is unreliable. Stainless steel
can fail suddenly if it is in contact with stagnant water (like in a closed rudder) and regular steel
will rust. Either way, some folks just dry it out, patch it up, and have no problem for years. Other folks lose a boat that way. Better to fix it, which unfortunately means either replacing it outright, or opening it up and exploring.
There's supposed to be a place in Maine
that also does custom rudders...the West Systems epoxy guys mentioned them in their newsletter some time back, they might be able to tell you who to contact.
I suppose the move from Florida
to Cali means something changed at Foss...but I'd still be scared to have anything custom made by them if the same folks were in charge. The freight charges on something that big are too substantial to want to deal in remakes.