Seems to be a normal problem and from all the feedback on this list I decided to leave it alone rather than replace or attempt a rebuild and I just make sure I drain it in the winter. I am pretty sure that the metal components in my rudder are already encapsulated based on a few exploratory holes I drilled and latter filled with thickened epoxy). For the first two winters I drilled a hole into the foam near the bottom (about 3 1/2 inches up from the bottom in the middle of the rudder on my C&C34 is where the foam starts) and let it drain for the winter on the hard - then patched with epoxy and some barrier coat followed by bottom paint in the spring. The first year, I also drilled a hole near the top but this didn't seem necessary as the water will eventually come out of the foam either way. This spring I decided to install a removable plug which I made myself using https://www.mcmaster.com/50785K213 and https://www.mcmaster.com/4429k111 (I cut the pipe fitting in half and only used one end). Drilled hole with appropriate hole saw, cleaned it up and bonded the fitting in using 5200. I thought about using epoxy but figured that with different thermal coefficients the 5200 might be better. I'll barrier coat and paint over it as usual. Hopefully in the fall when back on the hard I can simply unscrew the plug and the pipe fitting will stay put.
Nathan Post S/V Wisper 1981 C&C 34 Lynn MA
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