rudder delamination

[pcker]

I just hauled out my Beneteau 28 for the season and found that my wood core rudder lost its composite lamination on one side. Water leakage was most likely the problem. The wood core will have the winter months to dry. I assume I'll have to pull the rudder. I am looking for suggestions on relaminating,ie. what product(s) are best to use to restore the lamination, and can you steer me to some procedural instructions. Thanks.

[barnakiel]

Google more. I remember at at least one website discuses this with picture.

Also look up Jefa website as they show how they build, what the structures are, etc.

Cheers,
b.

[S/V Illusion]

Better do a thorough inspection of the webbing and weld joints holding the webbing to the rudder post. If rusted or weakened, no amount of re-coring will fix that.

[DeepFrz]

What kind of wood is the core made of. If plywood it is probably saturated. Make sure there is no wood rot before you reskin. Pictures may help people help you.

[Cheechako]

Open your rudder up so it can really dry, it wont dry closed up. You can inspect that way too.

[a64pilot]

What does a new rudder cost?

[pcker]

I hope this attachment shows the photo I took of the rudder. Now examining it, I see this has happened before. The plywood has screws in it. The boat was built in 1977. I have owned it 5 yrs. Each year before launch, I have inspected the rudder, and I have noticed a crack in the composite covering which I have repaired with a layer of fiberglass. Evidently,that was not sufficient to do leak proofing. Maybe my best shot is to remove all the covering and reconstruct. Any advice on the most reliable covering? Gelcoat on top of fiberglass?

[Cheechako]

Glass epoxy. Forget the gel coat. Maybe a good barrier coat. That looks pretty far gone. Sometimes you can cut at forward or aft edge and peel off the outer glass layer and use it to establish shape for a new one adding more layers of glass over the existing metal framework.. Not sure with that one though. Do you know how the gudgeon attaches to get the rudder off?

[pcker]

Just above the rudder is a sleeve over the shaft with two bolts to secure the rudder. I assume that sleeve functions like a plumber's nipple, and that should make removal easy. Thanks.

[rognvald]

Originally Posted by S/V Illusion

Better do a thorough inspection of the webbing and weld joints holding the webbing to the rudder post. If rusted or weakened, no amount of re-coring will fix that.

This is good advice. Before any repair is considered, you must determine the structural integrity of the rudder frame. If this is fine, the repair is straightforward and simple. Keep us posted on your progress. Good luck and safe sailing.

[UNCIVILIZED]

Realistically you need to start over. Meaning that assuming the framework is solid, which isn't a given. Then you're better served by building a rudder which has a rot proof core, preferably one that's impervious to water. Either a proper mix of epoxy & fillers (best), or high density foam. Along with a flexible seal at post, & the blade skinned with glass & epoxy. Followed by fairing, sealing, & painting.

[pcker]

Thanks everyone for useful advice.

[Island Time O25]

Here is a good step by step "how to" in 6 parts.

https://www.youtube.com/watch?v=MRXNnFx7DBQ

[CSY Man]

If the rudder is still hanging on the boat and on the hard.
Drill a bunch of holes from the bottom up, as many as you can with a long drill bit.
Then run hook a small air compressor to one of the holes and let it sit and run for hours and days. It will slowly dry out the rudder. When you think it is dry, let sit a few more days, perhaps with heat lamps pointing at the bottom. Then get a bunch of dowels from Home Depot, dip in epoxy and jam up in the holes you drilled.
A day or two later, chisel off the dowels sticking out, sand, epoxy again and paint.
Total cost about $25 if you already have the compressor. (Black and Decker electric type for filling tires on your car)

Did the above 15 years ago and still good.
No sh!t.

[pcker]

CSY-- Your plan is one is good engineering and I'll plan to follow it. BTW, this area is the shore of Lake Superior, and I'm on the hard for 7 months. The rudder will be off and in my basement drying out. Thanks.