Rudder Autopsy; good and bad news

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Oct 7, 2008
379
Oday Oday 35 Chesapeake Bay
Some of you may remember that under a previous post I wrote about replacing my rudder because there was rusty water coming out of some cracks that were exposed when it was peeled along with the bottom of the boat. My decision at that time was based on the idea that perhaps the iron perpendiculars were rusting and eventually going to break free from the stainless steel rudder post. The only way to know for sure was to do an autopsy of the rudder which would have resulted in a complete rebuild. Therefor thinking it would be better safe than be sorry I purchased and installed a new rudder. Well I finally got around to doing the autopsy of the old rudder. Here is what I found. First the good news... The perpendiculars were securely attached to the rudder post. They were rusted but the attachments would have lasted for many more seasons. Now the not so good news: It looks like a PO had rebuilt the rudder once before. The iron pieces were encased in marine tex and then fiberglassed and epoxied in place. Now the new question is was this done because they were breaking free or was the rudder rebuilt for some other reason? The original rudder is 26 years old. It was partially water logged and showed signs of many repairs. Could I have gotten by with a few more coats of epoxy and paint? A definite maybe! Here are a couple of pictures. A surgeon I am not.
 

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DannyS

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May 27, 2004
933
Beneteau 393 Bayfield, Wi
I'd love to see a few more shot from a little farther away for some perspective. Also the spot where the post enters the rudder. I think that's where the water most likely entered my rudder.
 
Oct 7, 2008
379
Oday Oday 35 Chesapeake Bay
Danny, Here are a couple of shots that give perspective. I did not go completely into the area where the post enters the rudder. There was a small hole in this area that I made larger. It was very wet there. The next time I pull it out, I'll concentrate in this area to see what I can find. I was suprised to see that the post had been welded together inside the rudder. I'm not sure if that was done as a repair or was part of the original design.
 

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May 30, 2006
354
Oday 34 Chesapeake Bay
Thanks for the pics and info. I find it curious that your rudder was fabricated with iron perpendicular members. Karma's was built using 3/4" stainless steel. Karma is a 1981 O'Day, I suppose that they changed rudder manufacturers between the years.

I agree with DanS that the most likely place of water intrusion is in the rudder stock union.
 

BarryL

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May 21, 2004
1,068
Jeanneau Sun Odyssey 409 Mt. Sinai, NY
Hey,

That doesn't look too bad to me.

Barry
 
Oct 7, 2008
379
Oday Oday 35 Chesapeake Bay
When I purchased the new rudder from Foss Foam they told me that they originally made them with iron/steel perpendicular members. They used stainless for the new one. Maybe it depended on the bid they had at the time for the rudders they were making. Oday probably contracted with Foss Foam as did most sailboat manufactures at that time.
 

DannyS

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May 27, 2004
933
Beneteau 393 Bayfield, Wi
I'm impressed by how clean the fiberglass removal was. Was there significant delamination?
 
Oct 7, 2008
379
Oday Oday 35 Chesapeake Bay
The fiberglass did not come off easily at all. It was necessary to cut it out with a recipricating saw and then use a cold chisel to peel it back.
 
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