Hi Josh, Based on the well documented report of your rudder repair, I decided to tackle this job myself for my 34+ which has the same rudder shape as yours. You mentioned 4 lbs. foam -- is this 4 lb./cubic ft. density? I have the skin removed from one side and the old saturated foam removed. The welds seem to be OK and the inside looks pretty much like yours except that there is a lot more epoxy or whatever resin they used around the leading edge. After I let it dry out for a few more days I'll pour the foam and then begin the glass work. Thanks for sharing the pics of the project.
Monty Scandia 1991 C&C 34+ Annapolis, MD On Wednesday, February 13, 2013, Josh Muckley wrote: > Hey everyone just wanted to share some pictures of the rudder rebuild on > my 1989 C&C 37+. Steve Uhthoff at Annapolis Gelcoat and Fiberglass did a > fantastic job and gave fantastic support. > > As a bit of a background on the boat and the rudder. I bought it May > 2012. At the time of the survey it was noted that the rudder had high > moisture though no movement over the shaft was noted. The exact extent of > condition could not be determined. I decided that the rudder was > absolutely going to be the first repair project during the winter haul out. > > Steve identified a specific design deficiency in that the stainless steel > arms were not bonded to either of the skins. Little or no stiffness was > being provided by the arms. He did on the other hand find that all of the > welds and the shaft were completely encapsulated and that no oxidation had > occurred. He removed all of the old foam core. Bonded the arms to one of > the skins. Re-foamed the core with 4lbs foam. Created bonding pads in the > core so that the arms could be bonded to the new top skin. He fiberglassed > the foam in place with 7 layers and vinylester teeing. Finished it off > with 3 coats of barrier coat and faring compound on both sides. I probably > mis-stated some part of the job being that I am not an fiberglass expert > but the long story made short is that I am exceedingly happy with the > outcome as well as the knowledge, expertise, and professionalism > demonstrated by Steve and his staff. > > Regardless of where you get your rudder rebuilt I hope the pictures help > some of you to at least pre-plan by seeing what you are getting into. Good > Luck. > > Annapolis Gelcoat & Fiberglass Repairs > P.O. Box 3438 Annapolis, MD 21403 > Office: 410-263-8980 > Fax: 410-280-2639 > http://www.annapolisgelcoat.com > > Josh Muckley > S/V Sea Hawk > 1989 C&C 37+ > Maryland > > -- > Want to email me privately? > Check out: http://en.wikipedia.org/wiki/GNU_Privacy_Guard > Then get my public key at: > https://docs.google.com/file/d/0B8pEh5lnvP1yU0R5RHBOS2h3MFk/edit >
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