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Old 01-04-2012, 13:30   #1
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Location: Wellfleet, MA
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Rudder Repair

Hello all,

Last summer our rudder snapped while we were sailing. We saved the broken piece and have been trying to engineer a repair or find a way to create a new rudder. Does anyone have any experience replacing a rudder? We were thinking of using a piece of marine plywood and shaping it and sealing it. Would that work? We've also been searching for boat yards and on Craigslist attempting to find an new rudder/tiller combo but that's proven unsuccessful. Any ideas on good places for parts in the Central MA/Cape Cod areas? Thanks!
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Old 02-04-2012, 14:44   #2
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Re: Rudder Repair

I would suggest taking patterns from the existing pieces, removing all the wood from the stock, to build a new rudder shaped according to the patterns, then covering the plywood with a few layers of glass cloth and epoxy, to add strength and protect the wood from water ingress.

Alain
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Old 02-04-2012, 15:33   #3
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Re: Rudder Repair

Never used these guys, but they might be a good source...

http://newrudders.com
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Old 02-04-2012, 18:26   #4
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Re: Rudder Repair

Excellent! Thanks so much. We'll definitely check out that website. We visited a West Marine store today and the staff recommended plywood covered in fiberglass and epoxy as well. Thanks for your help! Happy sailing! :-)
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Old 03-04-2012, 05:04   #5
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Re: Rudder Repair

Greetings and welcome aboard the CF, Pnickoiler.

I second Foss Foam.
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Old 06-04-2012, 19:29   #6
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Re: Rudder Repair

D&R Marine in Assonet MA made the new rudder for my Pearson 34 a few years ago. Good work.
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Old 06-04-2012, 20:25   #7
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Re: Rudder Repair

For replacing balsa core, I like 5 lb. rigid urethane, usually use Airex. For a rudder core I like to use a high density closed cell like 10 lb. or even 15 lb. Airex. Once you get up to 15 lb. it becomes very hard to shape. A powerplane still makes quick work of it though. The higher density has superior impact absorption and rigidity. 15 lb. is hard to dent with a hammer. If you go up to 25 lb. it's like cement, you can't cut it with regular blades anymore.
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