I have an 85 28.5 and have noticed sever buldging of my rudder on one side. With a sharp hit I can hear water sloshing around inside. Does anyone know where to get a replacement and approximately what they cost. I'm not worried about it falling apart this year, but with that much water inside I don't want to go through another winter and have it freeze & crack everything apart. Is there perhaps a cheaper alternative than replacement. As usual the help from this site is appreciated.
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Doug
Call Hunter Marine....
First....DONT WAIT! The last you want to loose is steering ability in heavywinds and deep water. You should check it out now. I called Hunter Marine and found out for our year and model it was a company on the east coast called Foss Foam. They told me that if we send out rudder to them they can strip all of it down to the metal frame, inspect integrity of the metal frame, fill with better foam that was used 10 years ago and put a better skin on it than the original (not seams) for $800.00. We don't have the integrity problems you describe,just a little weeping. But we are getting it done before next season. There have been some articles in Sail mag and Cruising world lately about rudders and the importance of keeping them strong. I did not realize how many boat catastrophies stemmed from failing rudders. good luck doug ps. greg emerson at hunter is very helpful.
First....DONT WAIT! The last you want to loose is steering ability in heavywinds and deep water. You should check it out now. I called Hunter Marine and found out for our year and model it was a company on the east coast called Foss Foam. They told me that if we send out rudder to them they can strip all of it down to the metal frame, inspect integrity of the metal frame, fill with better foam that was used 10 years ago and put a better skin on it than the original (not seams) for $800.00. We don't have the integrity problems you describe,just a little weeping. But we are getting it done before next season. There have been some articles in Sail mag and Cruising world lately about rudders and the importance of keeping them strong. I did not realize how many boat catastrophies stemmed from failing rudders. good luck doug ps. greg emerson at hunter is very helpful.
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Ron Barrow
Doug is right and.....
I have just finished rebuilding the rudder on my '89 Hunter 33.5. I should have called Foss. $800 does not sound bad considering the hours and materials. To repair with much help and advice from the boatyard and friends, first a few (eight or ten) 3/8" holes were drilled all the way through the rudder at various locations in lower sections and watched the water drain. The boat was out of the water all winter, so the rudder had plenty time to dry. (Dryness is important.) There were many blisters which were also opened to dry. The repairs pretty much follow a traditional bilster repair job with a few added tasks. Sheathing fiberglass tape around the perimeter to prevent separation, filling the holes with epoxy resin, fairing with of Epiglass epoxy with appropriate fillers for below the waterline use added to save weight and to make sanding and shaping easier. The individual tasks involved are relatively simple, but they must be done in sequence and often require waiting for coats of epoxy or filler to dry. Since my boat is 125 miles away, I brought the rudder home to do this work a little each day. If you try this, don't forget that the rudder with the stainless steel post is heavy, hard to handle; and, you often need access to both sides at once. At noon today, I applied the last coat of 2000/2001 epoxy barrier coat as she hangs from the rafters of my garage. One more sanding and then bottom paint.... Now I read Doug's message that the foam and materials that I have been earnestly trying to preserve are inferior.... Rich, there could be other problems like rust with the inner frame that could cause failure at the worst possible time, etc. Take Doug's advice and DON'T WAIT. My advice: Spend the money on a new rudder or have Foss repair and replace the inferior stuff. Good Luck, Ron
I have just finished rebuilding the rudder on my '89 Hunter 33.5. I should have called Foss. $800 does not sound bad considering the hours and materials. To repair with much help and advice from the boatyard and friends, first a few (eight or ten) 3/8" holes were drilled all the way through the rudder at various locations in lower sections and watched the water drain. The boat was out of the water all winter, so the rudder had plenty time to dry. (Dryness is important.) There were many blisters which were also opened to dry. The repairs pretty much follow a traditional bilster repair job with a few added tasks. Sheathing fiberglass tape around the perimeter to prevent separation, filling the holes with epoxy resin, fairing with of Epiglass epoxy with appropriate fillers for below the waterline use added to save weight and to make sanding and shaping easier. The individual tasks involved are relatively simple, but they must be done in sequence and often require waiting for coats of epoxy or filler to dry. Since my boat is 125 miles away, I brought the rudder home to do this work a little each day. If you try this, don't forget that the rudder with the stainless steel post is heavy, hard to handle; and, you often need access to both sides at once. At noon today, I applied the last coat of 2000/2001 epoxy barrier coat as she hangs from the rafters of my garage. One more sanding and then bottom paint.... Now I read Doug's message that the foam and materials that I have been earnestly trying to preserve are inferior.... Rich, there could be other problems like rust with the inner frame that could cause failure at the worst possible time, etc. Take Doug's advice and DON'T WAIT. My advice: Spend the money on a new rudder or have Foss repair and replace the inferior stuff. Good Luck, Ron
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Patrick Ewing
Check out Foss and Practical Sailor (May 15)
Practical Sailor has a letter from Foss Foam Products which gives a lot of detail on this problem. They mention $300 to $700 for a repair but that is not real clear the way it is worded. The most surprising thing to me was the advice given about having and keeping a detailed drawing of your rudder in the event that it is ever stolen. Apparently that is a common problem that they deal with routinely. contact: Bob Walker Foss Foam Products 4840 126th Ave. N. Clearwater Florida 727-571-3626 or Costa Mesa California 949-646-0244
Practical Sailor has a letter from Foss Foam Products which gives a lot of detail on this problem. They mention $300 to $700 for a repair but that is not real clear the way it is worded. The most surprising thing to me was the advice given about having and keeping a detailed drawing of your rudder in the event that it is ever stolen. Apparently that is a common problem that they deal with routinely. contact: Bob Walker Foss Foam Products 4840 126th Ave. N. Clearwater Florida 727-571-3626 or Costa Mesa California 949-646-0244
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Rod Leonard
Rudder
Get it redone at Foss Foam. The only time a rudder fails is when you really need it. Rough weather! I have broken two of them both time I was in the Middle Of Lake Michigan. When you brake one you can not sail or motor your boat! Look for a bulge 5 - 8" from the top of the rudder or signs of weaping rust. I have always taken good care of my rudders VC Tar and Kept it covered in winter. So I quess what I'm saying is when in doubt. Get it checked!
Get it redone at Foss Foam. The only time a rudder fails is when you really need it. Rough weather! I have broken two of them both time I was in the Middle Of Lake Michigan. When you brake one you can not sail or motor your boat! Look for a bulge 5 - 8" from the top of the rudder or signs of weaping rust. I have always taken good care of my rudders VC Tar and Kept it covered in winter. So I quess what I'm saying is when in doubt. Get it checked!
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Eric Lorgus
It may take a while
I bent the shaft on my 87H28.5 after a grounding last summer. Very slight bend, but it caused the top of the rudder to rub the hull. Took it to the marina who recommended a new rudder. They ordered one, from Foss Foam (I later found out). It was supposed to take 2 weeks. After 4 weeks, I did some detective work and found Foss Foam on my own. They hadn't even BEGUN the fabrication because they hire the metal work out to someone else, and were waiting on them. I gave up on the rudder replacement and took it to a machine shop to have the shaft straightened. They took one look at that thing and winced. They recommended grinding the top of the rudder just enough to give it clearance, which is what I did do. Rudder works fine now.
I bent the shaft on my 87H28.5 after a grounding last summer. Very slight bend, but it caused the top of the rudder to rub the hull. Took it to the marina who recommended a new rudder. They ordered one, from Foss Foam (I later found out). It was supposed to take 2 weeks. After 4 weeks, I did some detective work and found Foss Foam on my own. They hadn't even BEGUN the fabrication because they hire the metal work out to someone else, and were waiting on them. I gave up on the rudder replacement and took it to a machine shop to have the shaft straightened. They took one look at that thing and winced. They recommended grinding the top of the rudder just enough to give it clearance, which is what I did do. Rudder works fine now.
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Rod Leonard
Rich Macal
Rich, I would Advice you to have your rudder checked or replaced! There is a weld about 3-5 " from the top of the blade. It's possible that you may have factured that weld which leaves it very suspect to brake off in heavy air sailing.
Rich, I would Advice you to have your rudder checked or replaced! There is a weld about 3-5 " from the top of the blade. It's possible that you may have factured that weld which leaves it very suspect to brake off in heavy air sailing.
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