Thanks Josh...one of my next projects...

David F. Risch
1981 40-2
(401) 419-4650 (cell)


Date: Sun, 17 Mar 2013 13:34:43 -0400
From: muckl...@gmail.com
To: cnc-list@cnc-list.com
Subject: Re: Stus-List 1989 C&C 37+ rudder rebuild

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


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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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