Repair Tiller bolt hole in rudder

[cbourne200]

Guess we used tiller as a handhold once too often. As I was returning to marina, tiller came off in my hand.

Bolt holding tiller to rudder had torn out of rudder.

What is the best method to repair this rudder? There is no 'grommet' in the rudder through which the bolt goes, just a drilled holes in the fiberglass rudder.

 

[rgranger]

This is what I would do... i’d cut the damaged piece out with a jigsaw. Clamp a “damn” around the cut out using two of these epoxy squeegees

Then I’d fill in the cut using small pieces of chopped mat and epoxy resin. Let it cure and remove the squeegee damn. Fair and paint with an automotive enamel. I would then redesign the rudder mount so that the new hole is about an inch aft of the original. I would also add a SS ferrule to run the pin through

 

[cbourne200]

I started to do just what you describe, then had a thought about something I heard/read, that the skin of the rudder was the strength for the rudder. My original intent was to cut an inverted "V" so that the remaining rudder would provide resistance to the bolt pulling out of the rudder. With the SS connector for the tiller, I'll have to put bolt back in same place.
So I stopped and posed the question to people that I assume know more about fiberglass than I. Was thinking about using a grinder to cut out fiberglass like you would a normal FG problem, then using mat/resin to build up/wrap over the top of rudder.
Thanks for the ideas.

 

[JRacer]

Might consider your inverted V cutout but into the void epoxy a solid marine grade wood block slightly thinner than the O/S dimension of the rudder and glass over the block making sure the glass feathers out onto the remaining solid areas around the repair. Then refinish accordingly. And, over drill the hole for the rudder bolt so you can put in a SS bushing.

 

[cbourne200]

Would wood be less succeptible to wear than the resin? Understand the ferrule/bushing should stop any wear...
Wrap all in wetted mat? If I use this approach, would probably wrap over top and 5-6 in down rudder.
Thanks for comments.

 

[jibes138]

The tiller is putting a reversing stress load on the hole as you push it back and forth. The skin is fairly thin and not that strong for that loading. I would cut a piece out large enough for a metal or G10 insert to be bonded in then glass over the area with cloth and epoxy. Then drill the hole for the tiller. The loading will then be on the insert that in turn will spread the forces into a greater area of the FRP skin. A bushing just looks like a larger bolt to the FRP it will help but an insert will be more robust

 

[StargazerP303]

Go to a farm supply store and get a "female fence gate" mount. you may have to cut it down for the width but it will never have to be fixed again! see drawing attached. Bend tabs to your liking. Capt Rob

 

[cbourne200]

I have an old gudgeon where 'ears' broke off. I might use that.
I also have 3/4 Marine ply (used years ago to make a rudder for a 23' sailboat) that I can use for an insert.
Thanks for the responses.

 

[DArcy]

That doesn't look very strong to me. A hole through fiberglass is obviously not strong enough, it did fail once already. Since you are rebuilding it, I'd seriously consider putting some stainless steel cheek plates on or a stainless steel band wrapped around the leading edge. This is a seriously built rudder

Even a Laser rudder has a metal head

I know it will take some thinking to figure out how to fit the cheek plates into the existing head stock but just think about how you felt when it let go and imagine that feeling when it is blowing 40 knots and you are on a lee shore.

 

[cbourne200]

That is a seriously overbuilt rudder! I may try wrapping SS over the top, if I can find some prefab part. Don't think I can fabricate anything like that unless I go to a SS fabricator (rails, towers, etc...). Haven't started repair yet as heat index has been 103-106 since problem occurred. And at 72 I just don't handle heat well...
Thanks for pictures.

 

[cbourne200]

Oh, and if it's blowing 40 kts, I won't be out...