Rudder Repair Options

[Matt Sanderson]

Al, Thanks for the great forum on rudder repair. I've learned a lot from the posts so far. I'll be repairing a delaminated area on my rudder this spring. The symptoms sound classic: football shaped bulges of about 1/2" on both sides of the rudder. I drilled holes in the bulges last fall to drain and dry the rudder. From some info I found in the West System books, I was planning on drilling more holes in the bulge at 1/2" intervals, injecting an epoxy mixture into the holes, and compress the skin to the foam with large wood working clamps. When the epoxy is set and cured, fair the holes, sand, and repaint. In earlier posts, you talked about cutting away the bulged skin and re-glassing- I assume with layers of glass cloth and epoxy. In your opinion, which method is best? I can be convinced to go either way. Thanks in advance.

 

[Al Walker]

To be sure...

Matt, Thanks for your nice note. This has been a real pleasure for me. Everyone has been great. To answer your question I have done it (injected and cut away)both ways. Usually if it's bigger than a softball I cut away the glass to make sure that the entire area is bonded. I don't know which came first the chicken or egg, but I do know that a delam proceeds water. If you have any questions while your are doing the repair please don't hesitate to write or call.Sincerely,Al Walker

 

[Mike Ross]

Best way to cut

Al,Whats the best tool to use to cut away the fiberglass? I'm thinking of getting a cutting bit to use on a dremmel (like a roto-zip) Would this work, or will I need to get a cutting wheel for a grinder? Obviously I want to minimize damage to the foam underneath. Any other specific tips for this repair would be greatly appreciated, such as re-glassing steps, fairing, and type of sander to use, or anything else you think would help a relative novice do the repair.Thanks again for a great forum.Mike

 

[Al Walker]

Repair

Mike, The type of tool you describe sounds fine. I use a cut-off wheel. Make sure that you cut or grind beyond the delam. Take care not to use a tool that will generate much heat. I have also caused a bigger delam with a grinder. The glass is only a skin, the foam will provide you with the shape. Relax, the difference between a good gloss job and a bad glass job is 2 grindings! Seriously have everything ready to go when you are prepaired to glass. You may not have time to go looking for something you need. Buddy up to someone who can walk you through it. Temperature and humidity are important factors to consider. What works for me in Florida may not dry til June for you. Good Luck,Al WalkerFoss Foam

 

[detlef Bruckner]

285Hunter rudder repair

I repaired my rudder a year ago.I cut out large sections of delamination on both sides in the fall and left it in a warm, dry basement.In january I took it to a bodyshop to reglass.I put some plastic over it and aplleid a heatlamp to check for moisture. After 5 minutes it was wet and after 10 the water started to poor out! I removed a lot more lamination and after 3 days of heatlamp it was finelly dry.It was amazing how much water that foam would hold, and it would not airdry. Good luck with your repair