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Rudder cut & cleaned out..jpg [ 625.5 KB | Viewed 0 times ] There's links and photos around here, but I don't think you have to go to the extent of laying up an all new rudder before inspecting what you've got. Block up high enough to get the rudderstock out.
I cut a "window" in the side of the rudder after I got it out leaving 4" or so all the way around the side of the rudder. I left the other side be. Then dig out all the old foam. That was the longest part. Turned out it was mostly pretty dry. Then check the attachment of the (two) stainless brackets off the rudderpost to the other side of the rudder . . . the stainless was tabbed to the interior of the PORT side of the rudder. Cut the STARBOARD side only. Check the tabbing, fix it, reinforce it if needed.
I foamed with 6#. Probably not heavy enough, but it was hard as a rock. I used a clear piece of Home Depot like acrylic window material taped and clamped solid to the rudder over the opening, stood the rudder up on end and carefully poured successive pours until I had to untape (Gorilla tape) and unclamp the acrylic and move it up for the last pour - the only one I had to really work/remove excess because the rest of it was kept in place and guided by the acrylic. I used West System and multiple layers of 17 oz biax and faired it out with the WS soft filler. You can't tell. Solid as a rock. Sorry about the order of the photos.
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Plexi & gorilla tape to contain expanding foam.jpg [ 645.06 KB | Viewed 0 times ]