Aquarius Sail Owners

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

What does the other end look like?

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.

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.

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.