Rudder Rebuild

I stripped the original rudder thinking it was in good enough condition to reuse. I sanded it down and filled the crack running down the center with West Marine Resin thickened with filler. The rudder had two aluminum bars each side that had been set into the rudder and was in effect a very good repair.

                                                                          

The aluminum fitting that mounted on the transom and joined the the rudder and tiller was cracked and was missing a piece at the top that held the butt of the tiller. This part was not available to purchase so I went to a local machine shop, Allied Machine Works, 438 West Watkins, Phoenix, AZ and had the piece reconditioned. The lip at the top was rebuilt and the shoulder cracks were welded and reenforced with an extra piece of aluminum.

                                                                                

The rudder had a warp to it and having done the reconstruction up to now, I decided to just make a new rudder. I bought a piece of Red Oak from Home Depot 3/4 " x 10 1/2 " x 3 ' for $25. I used the old rudder for a template and cut out the new rudder. It fits the aluminum fitting perfectly. Now I have to shape the rudder and Epoxy it. So far so good.

                                                                             

                                                    Shaped and ready for Resin (today!)

                                                         4th and last coat of resin curing