Bushing pressed down onto the epoxy/graphite mixture. Pictures are a little out of sequence.
The surface was very smooth where the epoxy stayed put. There were a few low spots. I mixed some some more and spread some more around with the putty blade. I had to do alot of sanding using plumbers sanding cloth to get it back down to size.
A couple gentle twists with some large channel locks, and the bushing snapped loose. Almost no epoxy stuck to it.
Applying the epoxy/graphite mixture. It wasn't a perfect science here. I had to do alot of sanding to get the fit right after I was done. Just get it as close as you can to make it less trouble to sand later. It took LOTS of graphite powder to get the mix to the right consistency. You do not want it to sag at all after you apply it, so make it good and thick.
Bushing pressed down onto the epoxy/graphite mixture. Pictures are a little out of sequence.
Mold wax for the bushings. Don't hold back and wait the full 10-15 minutes between coats. You DO NOT want the brand new bushing to stick to the rudder shaft.
West System aluminum etching material. I've got enough to do about 30 rudders if anyone needs some.
Rudder shaft showing wear and some pitting where the lower bushing rides. I'm not sure the extent of structural damage from the pitting. And although this repair takes care of the 1/16-1/8" worn surface, I don't think it will do anything to make the shaft stronger. Only time will tell if the rudder shaft ends up snapping away. Then it's $1600 for a new one.
drumbeater

Bushing pressed down onto the epoxy/graphite mixture. Pictures are a little out of sequence.

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Pearson 26 Rudder shaft repair
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