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Old 11-19-2012
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Re: Home made rudder for Catalina 22

Thanks for your reply!!

I did coat the rudder with one layer of glass mat plus another layer about 1ft over and under the water line, also it has two coats of epoxy resin, 4 coats of 2 part epoxy barrier coat and 3 coats of bottom paint; I trust this will help keep the interior filler and core dry, also I per-drilled the holes for the hardware bolts with 7/8" bit, filled with epoxy and re-drilled with the correct size bit to prevent water getting into the core via the hardware bolts (that was the problem with the original one). I figure it's not perfect, but, after seeing how catalina built the original, I can assure you this one should last at least as long as the original lasted; so about 12 hrs of labor for 30 yr of rudder is not too bad.
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S/V Chata
1980 Catalina 22

"Common sense is the least common of the senses"

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