Rudder repair – exploring what’s required to fix the cracks

Last year when I started the sanding the hull (preparation work for changing the bottom pain type) I found that I had some cracks in the top of the rudder. At first I thought it was just a small crack but then when cleared some of the sanding dust off I realized it was cracked on both the front and rear along the top and the vertical piece up the side of the rudder post.

I’ve have now drilled along the crack to determine how deep it is and determine how much moisture might have gotten into the core.   I found during the drilling that along some spots of the crack it was easy to drill through than others.  The spots I drilled off the crack was tough to drill through. I believe that means that the damage is just along the crack.  I am hoping that I can dremel out that channel for filling with epoxy.  I also plan to have to grind down along the top to lay new fiberglass for strengthening the joint.  The tricky portion will be the vertical round piece that follows the rudder post.

I have the rudder hanging upside down to check for draining any moisture that got in. So far I have seen nothing coming out so it could be that it is just along the surface of the fiberglass and no water got further in.