Rudder Hardware

[Bob Wingard]

Do any of you know who the manufacturer of the rudder hardware is for the 25.5? My rudder compressed at the leading edge where the Gudgeon attaches to the rudder. I found a SCHAEFER Gudgeon for a J-24 that is almost exactly the same size as the Gudgeon that came off the rudder (same height and width but 0.4 inches shorter). When I put this Gudgeon or the old Gudgeon on the new or old rudder it fits, but if I were to tighten it down it looks like it will pinch the leading edge and eventually create the same problem all over again.Bob Wingardnot currently sv Fair LadyPort Arthur Texas

 

[Anthony Bavuso]

Just repaired my rudder from a similar problem.

Bob,I just got through repairing the rudder of my 1985 Hunter 25.5 with a very similar problem. Actually in my case the lower rudder gudgeon broke and I had to have it rewelded. I tried calling around to find out if the original rudder gudgeon part was still being made by anyone. I called Foss Foam the makers of the rudder and they referred me to another company (I can't remember the name) who made the stainless steel hardware. I called them and they told me they stopped making the rudder gudgeon part many years ago. So I was out of luck finding the part from the original manufacturers. I also found the J-24 gudgeon made by shafer to be very similar. The biggest problem with the J-24 rudder gudgeon is that is requires 4 mounting bolts and holes while my rudder only had three holes. And not wanting to fill in the current holes and then redrill 4 new ones I was left with the only remaining alternative to repair my broken one. My lower gudgeon broke a very clean break right along the curved area on the straps on one side. The other side was developing a large crack too and would have also broken. I took the gudgeon to a welding shop and for $30 I had a really pretty stainless steel weld bead along both straps. Hopefully good as new, maybe better.I think the problem with the rudder is that that makers didn't really reinforce the area where the gudgeon attaches very well. The rudder is made of a thin fiberglass shell that is filled with some kind of foam. The problem is in the area around and between the gudgeon the fiberglass is not really thick enough and over time mine cracked. The fiberglass sheathing in the area between the gudgeon on the leading edge broke off and exposed the foam. I had to route out the foam about 1.5 inches deep and maybe 2 inches wide (I used a dremel) and then I filled in the cleaned out area with west system epoxy with a filler added. Been I think 3 months now and no problems yet.Also I think it is key that since in the area between the gudgeons that there is only a thin layer of fiberglass and then foam that the mounting bolts be only tighten enough to securely hold the straps against the rudder. So I think even in a rudder in perfect shape tightening the mounting bolts down too tight will damage it.

 

[Dave Weir]

Rudder Repair

I just finished the same repair following the procedure Anthony outlined, with one additional step. Filling the area you grind out with expoxy plus filler (coloidal silica or microfibers) will provide more internal strength than the original, but two or three layers of fiberglass cloth over the top of the repair will help the rudder stand up against the side forces applied at the gudgeon. For best results, apply the cloth after the filler "kicks" but before its inital cure--that way the whole job will bond chemically.One additional caution, if the cracks in skin extend into the thin fiberglass, you should probably grind the damage out to the first mounting hole, fill it and redrill. Otherwise, you are likely to cover up an internal weakness.As to the gudgeons, these are no longer available and having them made could get pricey. I had mine welded after speaking with Schaefer. The J-24 gudgeons are not as heavy as the 25.5's originals, and Schaefer said they would not stand behind them for this application.Good luck!