How best to repair this?

[jbshu24]

So this would definitely make the weather helm stronger. I'm wondering what the best way to repair this is?

Fill with JBWeld or PC-11 Epoxy? I'm wondering if the pressure of the roller would crack the epoxy out in one big chunk.
or does it need to be faired and filled with fiberglass mat/filler/woven?
Or should I just send it in to get repaired? i just hate to lose out on the few good sailing days we have in upstate NY.

thanks for any advice

[Kevin Keller]

What does the other end look like?

[jbshu24]

Other end is pretty good, white coating is rubbed off a little on the tip from where I scrape up onto shore. I think the roller bearing got stuck when coming to shore and it busted up the groove.

[Kevin Keller]

I guess I would use an epoxy/fiberglass slurry. You might want to drill a hole into the foam and epoxy a fiberglass rod so it sticks out a little to give the repair some more strength.

Make it oversize and then you can sand it sound to the correct shape using your other rudder as a template.

[Matt Haberman]

We have done this type of repair using layers of woven fiberglass and epoxy resin. You could build up the area with a epoxy filler first and then put layers of glass over it too. I would recommend removing the gelcoat (not fiberglass) from the sides of the rudder so you can wrap the glass onto the sides without making the rudder too thick.