Here .. Pull this
Join Date: Jan 2007
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Take the rudder off the boat. Take all the fittings off the rudder. I am assuming that you told us that the crack runs horizontally across the rudder.
Draw a straight line across the rudder, on top of the crack and saw it neatly in half. Do not sand the cut smooth. Now get some 1/2 inch or 3/8 inch diameter HARDWOOD dowels about 3 inches long - you want them to be about a third of the thickness of your rudder. (You might have to use smaller diameters as you get toward the back).
Drill STRAIGHT holes 1 1/2 inches deep, a tiny little bit - like 1/32 of an inch - bigger than the width of your dowels vertically into one half of the rudder. Shave down some pencils or something similar, and shove them into the holes that you just drilled. They need to stick out a little bit - about 1/16 of an inch.
Now CAREFULLY butt the two pieces of your rudder up together, so that your pencils mark the spots on the other half of your rudder where you need to drill corresponding holes. Take the pencils out and again drill STRAIGHT holes about 1 3/4 inches deep. Fill the holes in both pieces of the rudder with epoxy and cover both raw edges of the saw cut with a fair amount of epoxy.
Shove the dowels into the holes in one side of the rudder, and then put the other half of the rudder on top of them and push (or hammer if necessary) until they meet and your rudder is in one piece again.
Now clamp it with LOTS of clamps, putting something thick and perfectly straight in between the jaws of the clamps and the rudder so that the rudder ends up perfectly straight vertically. Now take some rope, and wrap it TIGHTLY around the rudder to hold the top and the bottom of the rudder together. Don't squeeze ALL of the epoxy out of the joint, leave a little bit in there - it is stronger than the wood.
When you are done, fill in any dings or holes with epoxy mixed with sawdust - should be the same consistency as LePage's Plastic Wood, sand it smooth, coat it with 7 or 8 coats of epoxy sealer (S1 low viscosity is very good for this) put the fittings back on, put it on the boat and go sailing.
Last edited by Sailormann; 05-10-2007 at 10:06 PM.