New Rudder

[ffoote]

Built a new rudder for a fellow so I thought I would share the process if anyone is interested. I started doing this many years ago when I got tired of fixing my crappy stock chia-pet of a blade. S2 quoted me 5K for a replacement so I figured I would have to build my own. I aquired a mould for a former S2'er and built my own. Then my buddy 'needed' one, then another guy...........
Anyhow here are some pics showing the process. This is the 4th rudder from me, and the 7th to come out of this mold.

We had quite a discussion on replacement rudders at a meeting before the Nationals in Holland (7-8yrs ago?) about what a legal rudder should weigh. I didn't see anything written into the class rules though. Can anyone shed some light on this? My blades have all weighed in the 33-38 lb range depending on how much Core-cell vs epoxy filler goes in. A dry stock blade should be in the 30-40lb range, an old wet one 50 to 60 lbs.

Now I am looking at buying another slam and the one I am considering, go figure, needs a rudder. Unfortunately it needs the whole tiller/ cheekplate/gudgeon assembly also which I can't make in my garage. Anyone have a lead or suggestion that might solve this dilemma ? Maybe a trade?

Frank

[dave]

"2.7.A.1. The minimum weight for the rudder assembly (rudder blade, box, gudgeons, tiller, normal hardware, and corrector
weight, if any) is 61 lbs. Tiller extensions are not part of this assembly. Corrector weights, if any, are to be
permanently affixed to the inside of the tiller box, as far aft as possible."

A simple process of elimination would be to weigh a few rudder assemblies minus the blade to find out what the blade needs to weigh.

[ffoote]

Here are the pics resized so I can upload them.

[ffoote]

glassed and reinforced (probably dont need the steel tubes, just for insurance)

[ffoote]

try that again

[ffoote]

leading edge

[ffoote]

trailing edge

[ffoote]

profile

[Tom Elsen]

Hey Frank - Looks nice.
I know that Jim Kloss has great service from 'Tops in Stainless' for some repairs and other work.
And (I think) Tim Bosma had some box cheeks for sale and/or the capacity to make new ones.
Good luck.
What did you 'fill' the new blade with, and what did it weigh?

[Tim Bosma]

Thanks for thinking of me Tom, but it is Stef that has the rudder cheekplates. I have stayed above the waterline with the parts I have to offer.

[dave]

If your rudder cheek plates aren't above the waterline...................... well..............................

[ffoote]

Hi Tom,
Rudders are filled with CoreCell rigid foam. The foam is epoxied into the shells then the gaps are filled with thickened epoxy. The finished blade comes out around 38lbs. With the cheekplates and the rest of the hardware on the rudder assembly I'm sure the whole thing would exceed the class minimum weight by a few pounds.
Frank

[cdiehl7]

For the gudgeons contact Garhauer marine... I have in another post a picture of them with what I paid. They look really good and were half the price of anyone else. Garhauer saved the pattern so he can make more.

[LarryE-old]

I have read somewhere on this site that some of the early 7.9,s had rudder breakage issues. Then some changes were made to make the rudder better.
Two boats from this area #107 and a real early hull, I believe #30 have had the rudders break.
Does anyone have any idea when the rudders were improved?
Like to hear from others who have rudder breakage.

[Mark Rode]

I have hull 209. The rudder is foam cored. I also have a brand new rudder delivered by S2 in 1989. It has a solid core and weighs 12 pounds more than the original. I have had cracking problems (lucky it hasn't broken) especially. Most of the cracks have been in the head although there were a couple on the leading and trailing egdes. I also found a bunch of voids in the core. I just keep grinding and reglassing. I think I almost have it licked.