My new rudder was splitting after i hit bottom (i think i revealed a previous split), Here is what i did about it

Cleaned out the area - I used a razor blade, flat tip, and other torture devices to get anything lose out.
used some 50 grit inside and around the area.
blew it clean with compressed air



Created a pocket in the rudder and made an epoxy insert (west system w mill fiber and colloidal silica filler) - dry fit, add lots of thickened epoxy inside first, then pushed in the insert. epoxied everywhere...


used a dremel and got it close to the right shape (the board didn't need lots of shapping, most of the work was internal)


faired in the epoxy to shape, and then some gel coat in some small areas and chips



later painted with spray paint to match rudders :)



Then came the centerboards - they were 2" different length -





created a pocked and an epoxy wedge. dry fit it and then epoxied the snot out of it



I have card-board cut out templates / outlines of a properly sized rudder and a good center board that i use as templates


I sailed on these this weekend, More pics to come - more work to finish them up too



Edited by MN3 on Feb 23, 2015 - 06:39 PM.

I spent weeks repairing my daggers after each had an inch off the bottom plus gouges on the leading edge. I made forms similar to Andrew's and filled with resin, faired, sprayed gelcoat and faired again. They looked perfect!
Their maiden voyage was made in Dunedin and they performed great....... until I hit a submerged rock in the channel. Only one was damaged but I need to do the whole process over again!
GRRRR!