Rudder Fabrication

[heron237]

I've been searching around the internet for a cogent description of how one would fabricate a new rudder for my 1979 Trapper 300 26' sailboat. The 1 3/8" stainless stock broke off last summer. I was going to have the SS stock fabricated with the requisite tabs etc., then I started thinking about perhaps switching to carbon fiber to save weight. My initial idea was to make a form large enough for my dimensions, put the stock in sitting on balsa blocks in the proper position and fill the form with two part 80# foam. Use a power planer to form and wrap with fiberglass, and graphite cloth. Any links, ideas, thoughts would be greatly appreciated. Ed

[Orion Jim]

My source would be Foss Foam Products. https://www.newrudders.com/
There are Youtube videos available should you desire to design, engineer, and construct your own. Good luck.

[dannc]

I keep referencing articles on the Morgan's Cloud website. I should get a referral fee.

Morgan's Cloud has a couple articles on rudder repair, https://www.morganscloud.com/2020/03/08/planning-and-budgeting-a-refit-rudders-part-1-the-problem-defined

The link is for the first article and is likely behind a pay all. The website is worth the money. Just saw an article that popped up when I searched for the link I provided that I need to go read.

The link and the second article talks about how rudders fail and how to rebuild them. The articles also reference Foss Foam, https://www.newrudders.com/.

Later,
Dan

[MicHughV]

I don't know about carbon fiber...I'd stick with the s/s shaft....for reason....you need to weld some arms ( tabs) to this to extend to the rear of the rudder.....I would recommend at least 4 arms...then foam and glass...
I'd also weld some stubby tabs to the front of the shaft.... to allow the foam and fiberglass something to grip too...doesn't need to be much....enough to give some " foil" shape to the rudder...you don't want the leading edge of the rudder to be the rudder post...

[Spot]

I could watch them do this all day long...
https://www.newrudders.com/rudder-construction/

[MicHughV]

couldn't explain it any better than the link just posted..

[Compass790]

If you use a metal stock Avesta 2205 is even better than 316L but Composite would be my choice too.

[Steelshooter]

Have you checked out Sail Life on YouTube? Mads built his own rudder and posted a couple of videos showing the process he used.

https://www.youtube.com/watch?v=_IjN9Sgm2qs