Vertical spacing
I removed my rudder 2 winters ago because of similar complaints. I had vertical play and side to side play. The previous owner had purchased a new rudder (from FossFoam, I believe), but had not replaced the bushings. The old bushings were very worn, not only in diameter, but the flange was aslo worn down. The old bushings were a G10 material (fiberglass), and the new bushings from D&R were a delrin-type (looks like teflon). When you get the new bushings, there are 3 pieces. 2 actual bushings and one spacer ring. Even with the new bushings, there was a little vertical play left. So, I used the old spacer ring with the new spacer ring. Now I have very very little vertical play. I also found that the tiller attachment rod (that extends inside the rudder tube and is bolted to the tube) can also determine the vertical spacing. The bolt holes in the rod had become more oval than circular. Also, the inner diameter of the new rudder tube was larger (Stainless steel vs aluminum, so the walls could be thinner due to the strength of the steel). I used some washers and west system epoxy with fillers to repair the bolt holes. Everything is good and tight now. No slop. No matter what you do, you'll have to remove the rudder (even if you just want to add the spacer rings). Hope this helps.
