Rudder Repair

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Rick D

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Jun 14, 2008
7,186
Hunter Legend 40.5 Shoreline Marina Long Beach CA
The rudder hit the outboard prop and left an area about 3 inches by 1.5 inches and about a half-inch or more deep. My dock mates suggested just using marine plastic filler. I have a concern that this will cause a weakness. What do you suggest as a proper repair?
 
B

Bruce Niederer, West System

This damage shouldn't cause excessive weakness, but if you're concerned here is my suggestion for a repair that goes further than simply filling and fairing. sand the gouge a bit to form a bevel around the edge of the damage. The standard 8:1 bevel is not really necessary, but what you're trying to do is create a trough that you can partly fill, lay in 1 or 2 layers of fiberglass, then fair and finish. I'm assuming the rudder is not from a high tech one design or built with carbon. The model I have in mind is something like an Evelyn 32 as an example of a larger production boat with an outboard. With the site prepared, mix some epoxy and fill it to non-sag with either the 403 Microfibers or 406 colloidal silica and fill in the bottom of the gouge so you can a relatively flush surface to lay in a couple layers of glass cloth. The glass patches should be slightly smaller than the outside edge of the bevel so it can be easily faired. Laminate the glass in with unfilled epoxy right over the filler already applied. Once this begins to gel (it epoxy becomes tacky and is no longer a liquid, but is cured enough to have more epoxy applied without disturbing the previous layer)you can mix some more epoxy and add some 407 low density filler to non-sag to use as a fairing material. Slightly overfill the repair, allow it to cure, and sand fair.
 
May 12, 2004
165
- - Wasagaming, Manitoba
prevent prop dings

I added a 'peg' to the fin of my outboard. The rudder hits the peg when hard over and prevents it from getting dinged by the prop. I fixed my crazes in the fg by enlarging the cracks with a dremmel tool then filling with gelcoat and sanding to a final finish, then repainting.
 
Jun 3, 2004
232
- - -
Foam filled?

My rudder had similiar damages when I bought her. After letting the rudder sit in a warm dry location for the winter I roughed up the surfaces with sandpaper and filled/faired her with marine epoxy filler. Coated her with a couple of layers of bottom coat. When I pulled her this fall you still couldn't tell where I made the repairs. The rudder was foam filled. The patch held very very well.
 
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