If you have the small piece that pulled out of the rudder this may not be that difficult to repair, at least well enough to keep you sailing. If you don't have that chunk that pulled out then repair does become much more difficult and a replacement is the way to go.
I am working on my boat now and noticed that one of my rudders was well on its way to this same kind of failure. It was first splitting along the seam.
In my case what was required was to work some epoxy back into the split and then glass over the split using two layers of 6 oz. cloth. The rudder castings on these boats usually give you a little room so adding a single layer of glass to the sides of the rudder around the loose piece with the same added glass as in this image below may give you back the strength you need to keep things together.
You must sand the gelcoat off any area that you are trying to bond to. Since bond strength is critical in this kind of repair epoxy is the way to go. I think you could get one layer of 6 oz. on both sides of the rudder and still be able to install it, if it were too tight then it is a matter of sanding one side down until it does fit, if both sides had to be sanded down to fit then this would be a very temporary fix. You could add several layers on the top like I did since this is not a critical fit area.
I took the preemptive step of doing this same fix to the other rudder. You can see more images of this repair in my photo album on the rebuild of This End Up, under hull repairs and upgrades.
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dg
NACRA 5.2 #400
This End Up
Original owner since 1975
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