Join Date: Jan 2008
Location: Seal Harbor, Maine
Thanked 21 Times in 20 Posts
Rep Power: 9
Re: Wanted - Rudder for I-28
You can fix it!
I will be dropping the rudder for a cutless bearing replacement. Time to do a shaft inspection, too!! I have already repaired the skin of this boat's rudder. When I got the boat the entire surface of the rudder was spyder cracked. I assumed it had filled with water and frozen. It had been on the hard for several years in New England. The cracks were evenly distributed. I drilled some holes and drained a lot of water. I ground down the cracks, not through the skin, filled them with an epoxy resin and tediously teased into place fg mat, then added a layer of fg mat in epoxy resin over the entire skin. I carefully sanded and faired the surface leaving a continuous epoxy/mat layer surface covering.
The stuff that drained out of the rudder the first year was septic. I was going to drill out some large plugs for inspection at that time but decided to see how things looked after a season of coastal sailing. I did inject (GretStuff) into the holes I had drilled using a long feed tube placing the foam deep in the holes. I used a long 3/8 bit and drilled up from the bottom edge of the rudder as well as some holes up high. I repeated the hole drilling and foam injections for a couple of years and quit after no drainage or apparent "wasted" core showed up. No signs of the original surface cracks have ever appeared. I closed the holes with epoxy paste each time. It has worked so far! It looks perfect after 5 years of service and storage here in Maine.
Now I guess it is time for an exploratory dissection since I can take the rudder into my shop and a careful look.
Islander-28, Marshall Sandpiper