P26 Rudder shaft repair

[drumbeater]

As detailed on Dan Pfieffer's website, were doing our rudder shaft today. Used the same materials and I sure hope the bushing comes loose after the epoxy cures.

Mr. Pfieffer's pictures were taken a while ago and kind of small resolution, so hopefully these may offer some more detail for others. Thanks to him for his great detailing of this repair for owners of these boats that are still out here.

 

[drumbeater]

Action shots applying mixture to rudder shaft.

 

[drumbeater]

I'm not the most patient type

 

[drumbeater]

Finished product somewhat. I had to use channel locks to remove it. The oil filter wrench suggestion didn't work because the bushing was so slippery from the wax. A few gentle turns and it popped loose.

There are still low spots as expected and I'll fill up with epoxy. And some final sanding is needed also.

I used about 4-5 coats of Meguire's mold release wax on the bushing. Heavy coats and waiting about 15 minutes between coats. I would not rush this part. I was very paranoid about that bushing sticking.

It's hard to not mix way too much epoxy. I used 50ml of epoxy and 10ml of fast hardener. It took almost 24 hours to dry in 55-60 degree weather and with my heat lamps put on it after about 6 hours.

I'm going to use some plumbers sanding cloth to finish sand so I can keep the round shape as much as possible.

 

[PopeyePittsburgh]

Looks nice! I did the same three years ago, and so far it seems to be holding up.

In addition to epoxying the rudder tube, I ended up expoxying the bushings into the rudder tube: Initially, I used caulk to hold them in place, but the caulk quickly ripped once in the water. For the first year the pivot point was between bushing and rudder tube... obviously not good. The second year I epoxied the busings into place, using the rudder tube to ensure alignment.

Also, this year I took out the rudder, and noticed my original epoxy on the aluminum rudder tube is flaking just a little...!? I will leave it be for now, but may re-epoxy next winter.

(This winter I will epoxy the hole in the top of the rudder tube, where the tiller connects. It is a bit sloppy now, this should take care of that.)

 

[drumbeater]

If you need some etching chemical or graphite powder I've got enough left over for probably two more rudders.

 

[drumbeater]

We had to install the lower bushing while the boat was in the water. I went to a local pool store and found some two part epoxy putty that will work under water. I tried a test batch in a bucket of water and it worked well. Do not try JB Water Weld, it does not work under water regardless of what it says.
I came up with an ingenious way to pull the bushing up (see pictures) but it ended up with the bushing being such a tight fit, I had to knock it in with a hammer. I'll know how the putty did in a day or two, but I doubt as tight as the tube was, that the bushing will move at all.
To sand the old epoxy off the tube at the bottom, I used some hose clamps and attached a rounded wood file to the end of a 3'x3/4" dowel and inserted it down the tube from the cockpit. Worked well and I didn't have to get wet.