Re: Build Fiberglass Rudder
To keep the new rudder from being overly heavy and still be strong enough, you will probably need to build it with a foam core. Unless you can live with a "barn door", shaping it to be hydrodynamic could be interesting without a female mould. All this to say that making a fiberglass rudder can be a hassle, and that's why they're so much more expensive than you think they should be. Using the mahogany rudder and replacing the wood when the time comes - five years from now, perhaps, if you keep it varnished and painted well, or maybe in ten years if (as you suggest) you fiberglass it - might be the simplest, cheapest, and easiest solution. K.I.S.S.