I pulled the rudder off my 1977 Oday 27 for the first time to facilitate a cutlass bearing replacement. I found some significant corrosion to the shaft.
What I found is some pretty bad corrosion on the aluminum rudder shaft where it meets the rudder blade. Unfortunately, I don't have the money to just buy a new rudder this season, nor do I have the time to rip this one open this season and replace the shaft. I can do that next winter, but no way right now. Rather, I'm looking at some kind of repair.
What I'm thinking is to take the thing to a machine shop and have them add some aluminum to the corroded area which I will then hand file into shape and also have them make me an aluminum rod the exact diameter as the inside of the shaft which I can drive into the shaft, making it something like a solid shaft.
My other option is to pretend I didn't see anything and hope it survives the season and I'll fix it next winter.
Any thoughts? Anyone ever make a repair like this? Or have a spare Oday rudder for cheap?
Specs are as follows: the shaft is 2" OD, after wire brushing the corroded area, at the thinnest point, the shaft is 1.88" in diameter, and the walls of the shaft are approximately .39".
Pics of the damage are here: Photo Album - Imgur