New Bern, NC

Rudder rebuild

This is a separate post to show the rebuild from start to finish....ignore if you've followed along in real time.

 

At haulout, Duane found some play around the rudder post....and when he applied some pressure, the rudder body actually fell off the rudder post!

 

Cutting into the rudder to investigate.                                     

 

 

The weld attaching the mild steel plate to the stainless post had completely failed.  Thanks to Mark Cole for some timely advice as we plunged into this!

 

More cutting in to the rudder body.  The mild steel plate at the side.

 

Rod ready to go to the local welder. 

 

The rudder quadrant was pitted badly.

 

Off to the local sandblaster - $10 has it nice and clean.

 

Treated with some epoxy to seal that area.

 

 Rudder body starting to take shape.  Used slick thin whiteboard from Lowe's to form the shape with fiberglass cloth and West System epoxy.

 

More layup

Other side of the rudder.

 

One side finished.

 

If you ever are in the New Bern, NC area and need welding - American Fabricators did a great job replacing the mild steel plate with stainless - for $130.  (The plate looks rusty - it's not - it's just a film on the stainless plate)

 

Other side - made a small opening to be able to pour the foam.

 

 

A little hard to make out - but left part of the foam in place that will guide the repaired shaft back into place exactly where it was previously.

 

First of the pour-foam at the base of the rudder.  We used Composite Envisions 15 lb 2 part urethane foam.

 

Sliding the rudder post into the rudder body.

 

Rudder post in place.

 

The post slid in thru this slot - which was glassed over with cloth/epoxy.

 

 

Several pours of foam to make sure all the voids were filled with the expanding foam.

 

The foam was liquid to start with, in about 60 seconds it started it's expansion and was quickly rigid.

 

Foam complete, ready for filing to shape and overcoating with fiberglass cloth and West System epoxy.

 

Rudder assembly ready for re-install!

 

Back at the boatyard - we had asked the manager if it was OK to dig a hole for the re-assembly.  (About 2' was necessary)  Ed (from What If) and Duane reinstalling the assembly.

 

 

Reassembled the rudder quadrant/cables.  Installed a new lip seal from Tides Marine.

 

Rudder ready for barrier coats and paint.

 

All done!  

 Total cost about $500 for the welding, foam and West System components.  

We did inquire with Foss Foam Products in Florida- they have a Manta rudder mold that does not have the lip at the bottom.  They will make one for $1750 plus $250 shipping.  They are currently 3 weeks backlogged.  Not a bad deal but we didn't want to spend any more time in the yard than necessary.