H30 Rudder Rebuild

[Famos_Amos]

Well, I started in on the list of winter projects today with what I hoped would be a small job drying out the rudder and rebuilding the lower half-foot or so.. However, once I started poking some holes in this gremlin, I realized it was going to need to be a more extensive repair. The foam is absolutely saturated throughout and delamination has occured under most the glass and completely around the oxidized framework.
Have any of you rebuilt a rudder from a similar state of neglect? Any advice?

 

[Rich M]

I had a similar issue several years ago. I removed everything from the frame, being careful to mark the top of the rudder on the shaft. I then sent the frame to Foss and had them rebuild the rudder. If it were to happen again I do think I would attempt to rebuild it myself. I didn't have the time then.

 

[Famos_Amos]

I had a similar issue several years ago. I removed everything from the frame, being careful to mark the top of the rudder on the shaft. I then sent the frame to Foss and had them rebuild the rudder. If it were to happen again I do think I would attempt to rebuild it myself. I didn't have the time then.

Did your frame look like this when you opened it up? I'm worried the frame itself will be corroded beyond salvage.

 

[Navicula]

I have often wondered....why not beef up the frame and skin with stainless steel

 

[Rich M]

My frame was solid and with cleaning I saw no rust or weak welds. It appeared to be stainless steel. My suggestion would be to make drawings of what you have to guide in the re-building if you choose to do it yourself. Also photos of the people from every angle. Good luck

 

[Famos_Amos]

My frame was solid and with cleaning I saw no rust or weak welds. It appeared to be stainless steel. My suggestion would be to make drawings of what you have to guide in the re-building if you choose to do it yourself. Also photos of the people from every angle. Good luck

I think I'm gonna carefully dig the frame and post out, have a welding shop replicate the steel portions (the rudder post is stainless welded to a steel lower with steel plates for a frame) and rebuild from there. Probably alot of work, but will save a few pennies. BTW- my best angle is on the taking side of the camera.. haha I know what you meant though- I will post pics (of the rudder progress)

 

[Famos_Amos]

Quick update-- I let the rudder air out with the top skin opened up as well as holes through the remaining skin for a couple of weeks. I started chipping away at the foam again, and it is still as wet as when I started. Aside from the moisture and discoloration, the foam itself seems extremely rugged, almost to the point I'm wondering why remove it at all? The steel frame has me worried, as it is apparent that at a minimum I'll have to get to the other side to clean out the wet/rotted foam and rust. I'm still thinking I should remove the post and frame and have the steel portion rebuilt. While this would put my mind at ease as far as the oxidation is concerned, the problem of chipping out the rest of the wet foam will remain and, despite the saturated state, it remains firmly bedded to the glass skin.

FWIW- it looks like the majority of the rusting started as water was able to enter the top of the rudder post and sit in the bottom steel portion of the frame. Originally, the manufacturer filled at least part of the post with expanding foam to mitigate this, but it has since rotted away, allowing water to leech in, eventually saturating the foam. Also, it appears at some point the rudder was dragged on the bottom (at least once) so, the gaping hole through the glass on the bottom didn't help.