Water logged rudder

[Halipeno2]

I have a 1995 Hunter 35.5 Legend, I removed the rudder to replace the plastic bushings because they had too much play. In the process I found out that the (Foss) rudder is water logged and I want to repair it. I have the new bushings and ready to install them but I could use any ideas and tips on how to repair the water logged rudder.
Thank you in advance.

 

[Don S/V ILLusion]

had a similar experience once and it was cheaper to replace the rudder than repairing it as the steel webbing welds were rusty. At a minimum, you should open it up to examine the damage after which you will be able to make an informed decision whether it is repairable.

 

[DArcy]

If you are a DIY guy you could look through the Boatworks Today videos on rebuilding a rudder. Someone at my club followed the instructions in these videos and successfully rebuilt his rudder.

Rebuilding A Foam Cored Rudder Part 1 | Boatworks Today

There will be more follow up videos showing the entire process start to finish. If you have any Q's please post them below! Thanks for watching :-)…

www.boatworkstoday.com

If you are going to go with a replacement rudder, you could try Phill's Foils. I don't see Hunter 35.5 listed on their site but I've heard they will build new based off the old rudder.

Phil's Foils A-Z, Sailboat Rudders, Daggerboards, and More | Competition Composites Inc.

New rudders, foils, daggerboards, centreboards

cci.one

 

[Dave Groshong]

The time and effort/expense, to rebuild a rudder is probably 75% the cost of a new one, when saturated with salt water, the steel skeleton rusts, so likely even a nice repair will be weak.

Rudders, Foam

Rudders, Foam

shop.hunterowners.com