Rudder damage - how to repair

[repawn]

Well - the weather has been alright for the last few days and I have gotten a few hours to work with the boat. I pulled everything out - the cushions are in rough but somewhat serviceable shape (for now), the sails are dirty and will need cleaning, and I don't appear to have my boom vang. I have discovered another leak but not the source - I am concerned that it may be the rub rail or the forward port side toe rail - the v-berth plywood is quite damp about halfway up the port side.

In addition - the rudder has a weird bit of damage to it - here is a picture:


Not sure what it is - the rudder weighs rough 35-40 pounds and appears to be solid but a little scratched up - this "hole" is dry. I am considering just pouring some epoxy in it - but would appreciate a more reasoned response.


On a positive note: I have vacuumed out all the junk in the boat - can't wait to actually clean it and suction out all the water from the bilge (not much) I have an order of bed-t butyl tape on the way as well as some west systems epoxy, hardener and cabosil - I plan on potting and rebedding all the deck hardware starting with the known problems - I may have to do some core repair as well.

I suppose at some point I should just create a blog with a link to show my status - maybe will start that soon. Thanks again for your help.

 

[Cmp1110]

Check out boat works today on YouTube the guy has a whole series on rudder repair it is pretty good

 

[DannyS]

This is how I fixed my delaminated rudder. It would be the same type of repair for you.
http://forums.oday.sailboatowners.com/showthread.php?p=744783&highlight=rudder%20delamination

 

[njlarry]

Danny, could your repairs have been done with the rudder on the boat?
Do you remember how heavy it is?
My '84 has about the same areas of delamination.
Also, other than crevice corrosion concerns, I wonder if some areas of delamination could just be monitored. It is very hard to find rudders more than a few years old that do not have increased moisture readings so if I do repair mine, I expect that without annual fall draining more issues will develop over time.

 

[repawn]

Delamination makes sense - do you think I need to open the rudder up any further or just grind around the hole? Would I replace the bit of missing material or just pour epoxy in - the rudder is off the boat and based on the last registration of the boat it hasn't been in water in at least 10 years - so the rudder is quite dry at least. One more project - going to be a long winter.

No real time to work on the boat yesterday - but I did look at the forward port toe rail and I was able to easily wiggle a section - so my guess would be that is a leak location.