The link for pictures was in a post from a few weeks ago.  Here's the link
again:

https://docs.google.com/folder/d/0B8pEh5lnvP1yVUdWUDNxVGFUcDA/edit

Josh Muckley
S/V Sea Hawk
1989 C&C 37+
Solomons, MD

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On Mar 17, 2013 11:07 AM, "David Risch" <davidrisc...@msn.com> wrote:

> Josh,
>
> I missed your pictures.  Where are they?
>
> Thanks!
>
> David F. Risch
> 1981 40-2
> (401) 419-4650 (cell)
>
>
> ------------------------------
> Date: Sat, 16 Mar 2013 22:08:16 -0400
> From: muckl...@gmail.com
> To: cnc-list@cnc-list.com
> Subject: Re: Stus-List 1989 C&C 37+ rudder rebuild
>
> Glad to hear I was able to help.  Steve used heaters and fans for almost a
> week to dry mine.  He also sand boasted the remnants of foam out.  The way
> he described the foam it is able to withstand 4 pound per square inch.
> Don't forget to re-encapsulate the shaft and welds.  Also don't forget to
> bond the metal web structure to the skin on both sides.  The side on bottom
> is easy, just use thickened epoxy and fill in the space.  Then add some
> fiberglass mat.  Once you have the foam in and shaped, cut out an area on
> each metal web where you can back fill with thickened epoxy.  This will
> allow the top skin to be bonded to the web.
>
> One more thing he told me was that the fiberglass mat he used was wrapped
> around to the other side almost 4 inches all around.  This prevents
> splitting at the seams.  He raved about a mat that is woven on one side and
> chop on the other and appears to be "quilted" together.  He said that the
> resin doesn't stick as well between two woven mats but cropped mat is
> weaker so the product he used/recommended capitalized on both strengths.
> He said the original skin was "flimsy" and probably only 4 ply.  He made
> his 7 ply.  He also fared and block sanded both sides due to the
> considerable deformation that had occurred to the uncut side from years of
> freeze/thaw.
>
> Thanks for keeping me posted, I look forward to updates.
>
> Josh
>
> --
> When security matters.
> http://www.secure-my-email.com
> On Mar 16, 2013 9:35 PM, "John Schumpert" <jmschump...@gmail.com> wrote:
>
> 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
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