Hey guys - I am in the process of building a couple of rudders for my Ensigns. Although I have only been involved in the Class a few years, I have already had 2 encounters - on 2 different boats - with rudders delaminating. I am certain many of you have had similar issues. The original design is less than desired. I have had 2 stainless marine grade shafts fabricated and had the fabricator weld 3/8" threaded stainless rod onto the shafts. I am using Coosa Board for the rudders. I plan to drill 1/2" holes into the Coosa to accept the rods and prefill the holes with epoxy resin and then set in place. The threads and the extra 1/8" of width in the holes with the resin should secure the rods firmly to the new rudder. I have used a similar pattern for the rods taken from the original rudder design, but have extended the 2 larger ones to get them further into the rudder. The Coosa is a non-absorbent material. I also plan to fiberglass the rudders prior to securing them to the new shaft. May even gel coat them. This is where I am at in the build right now. Hope to get them glassed and ready for install soon. ** The Coosa rudders as shown are rough cut*** They still need to be further shaped and fine sanded.
I have actually cut 3 rudders from the 4'x8' -1 inch thick Coosa. I am hoping to pick up a 3rd boat (want spare parts!) for my project of trying to assemble an Ensign presence at my Club on Long Island. (South Shore / Great South Bay) My 2 boats are hopefully going to be incorporated into our sailing Programs this year and I currently looking for a 3rd boat to facilitate some racing.
We have a 2-Ton hoist so we can dry sail boats. Love the lifting eyes!