Adding a Rudder Skid Plate and Injecting a Hollow Rudder with Polyurethane

The original rudder was constructed with a hollow stainless steel frame welded to a solid 2.5 inch stainless rudder shaft. Cold molded wood made up the exterior. Like many rudders the bottom edge of the rudder was fractured letting water into the hollow interior.

The hollow cavity inside this rudder has been dried and injected with polyurethane sealant under high pressure. Then two layers of Dynel and epoxy resin were applied to the wooden exterior. Finally a heavy aluminum skid plate was bolted to the bottom and 1 inch of polyurethane sealant was injected between the aluminum shoe and the rudder. Note, the hand held grease gun threaded into the metal shoe. This was used for high pressure polyurethane injection.

Holes were drilled in hollow areas and air was forced through for several days to dry out the inside of the rudder. Then self leveling polyurethane sealant is pumped into the bottom holes until sealant worked its way out of the upper holes. As we worked our way up the rudder the holes lower hole were temporarily plugged.

Under high pressure, using a grease gun, polyurethane sealant was injected into the rudder around the rudder shaft until sealant oozed out of the joint between the shaft and the rudder.

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Under high pressure, using a grease gun, polyurethane sealant was injected into the rudder around the rudder shaft until sealant oozed out of the joint between the shaft and the rudder.

Diamond shaped washers were made for the bolts that attached the cold molded laminate to the hollow stainless steel core. The original 1 inch washers cut there way into the wood.

Then the wood was covered with two layers of Dynel and West epoxy

Finally a heavy aluminum skid plate was bolted to the bottom and polyurethane sealant was injected between the aluminum shoe and the rudder using high pressure.

 

Stan Sroga
stansroga@sailtraininginc.com
sailtraininginc.com

 


 


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