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Foss Foam, formerly of FL, was apparently acquired or merged and is in CA now.
I can tell you from having been through the process, the original I28 rudder was not all foam. It is a thick mild steel/iron plate (maybe 1/4"?) welded to the rudder stock, covered in foam then fiberglass. When the fiberglass develops even a hairlines crack--the foam saturates, the plate surface rusts, and it can hold a LOT of water without weeping.
We started with some exploration holes, routing out the rotted black former foam, and wound up uncovering over half of the plate. IIRC the plate extends through most of the top half or 2/3 of the rudder.
For want of any other source, it was replaced with a Foss Foam (FL) rudder. But, they have no records of the originals and I doubt they made them. They customized something else for the boat, screwed up the basic dimensions (which two of us measured, cross-checked, and cross-checked again on the order because shipping aint' fast or cheap) on what they built, so it had ot go back for a remake. Lost MONTHS on that mess, no compensation from Foss. And the new rudder is different enough to change the perfect balance to something just ordinary.
I'd strongly suggest avoiding Foss, and having your rudder rebuilt using the existing out skin, i..e having it split, rebuilt, and resealed if possible, or replaced by a glass shop that can do better reconstructions.
Never thought to weigh either one, but yes, with a steel plate in it, the original is heavy--wet or dry. If you drill some 1/4" holes and find black (not white/yellow) material behind them, that's foam degrading from water penetration.
I'd have to wonder, if you can save the skin (split it off) and then replace the foam with epoxy filled with glass microballoons, if that wouldn't be a better permanent solution. Pricey--but waterproof. Maybe the "new" company is run differently, but I'd be scared to deal with them.
Last edited by hellosailor; 01-29-2008 at 11:43 AM.