Rudder repair question

[Ed Ryan]

I understand that most rudders are made up of two halves of fiberglass with a core of some type of foam, not to mention the rudder post within. On my O35, the joint on the forward edge of the rudder appears to be a gap about 3/8 inch wide, filled with some sort of caulking. I have painted the rudder each year and it has held up fine, but this year the caulking in the gap is disintegrating. (By tapping the rudder surface over its entirity, it seems solid throughout, so I don't believe there's a water problem within the rudder at this time.) It seems like there are at least two ways to address the gap situation. One would be to fill it in with caulking, like 5200 or Lifecaulk. The other would be to epoxy a strip of fiberglass the entire length of the rudder, effectively covering and sealing the gap. Any ideas or suggestions as to what's needed?Ed

 

[Paul (Affinity C320)]

On My 1988 O'Day 35

I had some work done because the outer skin of the rudder had seperated from the core. The technique used was to drill holes all over the rudder, fill them with epoxy and turn screws into the core. Once it dried, the holes were filled with epoxy and the entire rudder was sanded and coated with Interlux 2000, 2001. The problem with some rudders is that they must be kept cool when out out of the water, this means it must be kept covered or painted white. I didn't do that for nine years so it started coming apart. The repair cost 500 and was cheaper than a new rudder. Seemed to work fine.Good luck.

 

[Calif. Ted]

When purchasing my boat I gave particular

scrutiny to the leading edge of the rudder and was able to convince myself of a hairline crack. Between myself, a surveyor and the boatyard owner we didn't think it was an open crack (or even a "real" crack) but decided to put an extra layer of glass along the edges. So, seems if the rudder is otherwise sound with no water intrusion, filling the gap with glass rope or roving, then a layer of cloth on the edges (as on the rails of a surfboard) would be an appropriate repair.However, it concerns me that the gap could be that wide. It would seem the foam must be expanding (water) to open it up like that.