I modified my ol'rudder on a 26D a few yrs ago, 3+in. leading edge and 8in longer, re-glassed and its worked great....but that was the only rudder I had, so I decided to make a new one. I watched all the post here on rudders I could, and decided to make a new one outta 3/4 Marine ply doubled up for 1.5 in. thick a 12% foil, 14 cord, 58in. long and a 56in. long .500 steel bar incerted 5in. behind the leading edge.= streangth + a lill added wght. so far its 4lbs.less then my ol'rudder.
Im getten ready to use the West syst. and close it up and start laying on the glass. gonna finish up the camber needed to give me the final 12% thats just missing when you use 1.5 thickness, anyway I'm gonna lay up a few pcs of cloth there and fair it in to get 12%
BTW I used a 4.5 disc from WoodCraft to shape out the rudder...I had it shapped out in 15 min. :dance: and a beltsander and 5in. orbital to fair it up. hope this gives U some ideas