Rumery's Boatyard
I just spoke with Wayne from Rumery's boat yard. First, I have to say that Wayne was very friendly and forthcoming with information. I really appreciate that he made the time to speak with me.
If I made good notes, here is the process:
1) remove quadrant from rudder-stock
2) from rudder area, remove large nut from rudder-stock
3) remove pintle screws or remove gudgeon
4) lift rudder-stock to allow rudder to pull out
At this time, inspect the pin on the rudder (that fits into the heel fitting) for cracks or chips.
Rebuilding rudder:
Wayne said that the rudder on Black Pearl was mahogany. They used the old rudder as a pattern and cut 3/4 plywood as replacement wood. Instead of tapping the wood, they overdrilled holes to 5/8 inch and epoxyied in a plastic tube that could then be machined to take the 3/8 inch bolts.
Now, if anything above looks wrong, it doesn't mean that Rumery's did the job wrong but most likely that I took inadequate notes and didn't understand completely.
Please fill in any gaps or incorrect statements that I made!