Questions about the rudder

May 23, 2016
1,024
Catalina 22 #12502 BSC
Things are moving along with my rudder rehab. I finally got the guts up to mix up the epoxy, and patch the damage. I'm not sure I can say it went well, but it got done. I learned a lot and it got done.

So, today, I mixed up gel coat and put three coats on one side of the rudder. I think it looks pretty good. Well at least it looks much better than it did. My problem is I now know what people mean when they say "orange peel". I have A LOT of orange peel. Do I need to sand it down until it is smooth? If so, what grits should I work through, and wet or dry sand?

Thanks!!!
good on you getting after these things (rudder & rigging)....you could be sailing this weekend, and that's likely record time from acquisition, compared to most (or all of us)! Well done!!!
 
Mar 23, 2018
63
Catalina 22 12491 Lake Charlevoix
good on you getting after these things (rudder & rigging)....you could be sailing this weekend, and that's likely record time from acquisition, compared to most (or all of us)! Well done!!!
Thanks, I needed to hear that. Last few days, and yesterday especially, I've been getting frustrated that we have been stuck at the dock. Drinking wine while sitting in the cockpit is great and all, but I'm ready to go sailing. Almost there.
 
Apr 11, 2017
571
Catalina C22 Solomon's Island, MD
Things are moving along with my rudder rehab. I finally got the guts up to mix up the epoxy, and patch the damage. I'm not sure I can say it went well, but it got done. I learned a lot and it got done.
Mission accomplished!

Depending on IQ, a mass of kicking epoxy can be a very fickle mistress. I had a little overhead fiberglass repair job last weekend and I'm still wearing 2 large clumps of strangely solidified and curly hair on the back of my head. People seem afraid to comment. Stuff holds great, and should last for years no matter where you put it. I just offer this as a cautionary tale so that others may benefit. I'm testing UV resistance this weekend..
 
Mar 23, 2018
63
Catalina 22 12491 Lake Charlevoix
Just realized I never updated this thread with pics. So here are a few of the final job.
In progress:
20180613_162937.jpg20180614_190908.jpg 20180614_190918.jpg
After:
20180618_200437.jpg20180618_200702.jpg 20180618_200721.jpg 20180618_200820.jpg

Certainly not perfect, but not terrible for a first timer. :) :clap: :waycool:
Thanks for all the help.

The only tip I can give is buy more gelcoat then you think you need. It doesn't go nearly as far as you think it will. Thankfully the guy at WM encouraged me to buy the bigger can. I would have run out for sure, then had to buy another can. :banghead:
 
Apr 22, 2016
161
Catalina 22 Folsom Lake
My ‘73 #2130 has a multitude of projects that I am slowly working through. The current item is the rudder. Take a look and let me know if you would leave it alone, how you would repair it or if you would replace. Thanks!
87CB93AD-34FA-4361-895C-4AB89FBBEF29.jpeg
DF390D03-B1AF-47B5-B6BA-21D7FAC598A1.jpeg
 
May 24, 2018
31
Catalina 22 Norcal
I don't blame you. With all that extra steel you probably need a crane to mount it. Might make a decent backup anchor, or a good way to handicap a faster racer.
 
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Jul 13, 2015
893
Catalina 22 #2552 2252 Kennewick, WA
Dayum @Sacto Dave — that poor thing! Definitely needs major rebuild— can’t tell from the photo if there's enough of the rudder to pull the rotten core, replace and reglass? Might be a delicate balance between between replacement cost and materials to rebuild.

Wondering if that lateral crack is through and through ? Or just on single face .... solid maybe, but you’ll spend some coin on epoxy
 
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Apr 22, 2016
161
Catalina 22 Folsom Lake
Ha! @pclarksurf no, that crack doesn’t go all the way through.
Might be a delicate balance between between replacement cost and materials to rebuild.
Everyone’s reaction so far was mine as well. Back when I first got this rust bucket, I got quotes on rudder options:
OEM rudder >/= $601
Kick up complete = $869
After market (NRL) = $549 D2146
for those #’s, I could get a bunch of epoxy.
Dayum @Sacto Dave — that poor thing! Definitely needs major rebuild— can’t tell from the photo if there's enough of the rudder to pull the rotten core, replace and reglass?
Ha! Thanks for the sympathy!
The core appears okay:
6E5FB2DB-9464-4939-8982-D2DCCE977D85.jpeg

Not sure what to make of what I’m finding inside. The bottom pintle appears welded as though torn apart:
9EA5B04C-D1D7-4A2F-991C-C80F3541966C.jpeg

How that could happen without breaking the core? Beats me. Maybe it was soaking wet and bent without breaking. Bond all around the core is cracked.
I’ve never done any fiberglass repairs, so I figure what’s to lose? Maybe gain some experience, if nothing else.
I’m trying to stiffen up the core by soaking it in epoxy:
69C62090-315F-4B7D-BC48-486830AE6F3A.jpeg

Like I did with the rounded-out hole for the tiller.
Been out to my waterskiing lake lately?
 
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Jul 13, 2015
893
Catalina 22 #2552 2252 Kennewick, WA
heck yeah-- you're on it... definitely worth giving it a shot, and a great piece to work on. Worst thing you'll do is sand off some extra. Good as new when you're done.
 
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May 24, 2018
31
Catalina 22 Norcal
That bottom pintle looks like the rudder has taken a few groundings and has been repaired at least once in its life. Mine looked very similar. The pin had been replaced and rewelded at some point in the past. Whoever did the work did okay, because it stayed together pretty well when the rudder struck a launch ramp curb and tweaked the bracket. The rudder took a little damage, the leading corner was crushed and I had to grind it back an inch or so to get to undamaged laminate.

Good luck with the rudder. I'm partway through repairing mine. I reshaped the lower corners and now I'm adding a few layers of glass to the edges. The rough work is mostly done so I'm going to take it sailing this weekend, I'll fair it later. I'm still new new to working with epoxy and fiberglass so there's been a lot of learning and extra sanding. So much sanding.
 
Apr 22, 2016
161
Catalina 22 Folsom Lake
Update?
Well, I’ve had a week off. We vacationed in Avila Beach, CA. Substituted mid-60°s for the 100°+ valley weather. Before I left, I filled about half the ground out area with epoxied glass. I’ll work on it tonight.
3D7962E4-052D-4BC3-8FF6-7133936B7886.jpeg