I have a related question on rudder construction. I had a rudder fabricated in aluminum. it is same dimensions as my old wooden rudder that had a fiberglassed cover. Will this rudder disqualify my boat from class racing.

thanks for the answers in advance.

Steve Wessels

ensign33

That's a lot of rudders! Did not realize that you were the owner of Ensign Spars at one time. So my question is: There appears to be a recurring problem with the rudders. Has anyone explored a different fabrication method? Has anyone tried a solid glass rudder? I seems to me that using glass over either wood or foam will eventually lead to issues. I'm using Coosa because of it's non-absorbent qualities and the Coosa is also very lightweight compared to the older wooden rudders.

2 layers of bias PY fabric would be plenty. I’d also use epoxy resin if possible. The west system pro set resin is a very good laminating resin. This is different stuff then the us all west system resin you’ll see at west marine etc.. 

Will do Vic. Getting ready to glass the rudders. Does anyone have suggestions on the cloth or mat weight to use? Number of layers? Thanks. Also thinking of putting a gel coat on.

Hey guys - I am in the process of building a couple of rudders for my Ensigns. Although I have only been involved in the Class a few years, I have already had 2 encounters - on 2 different boats - with rudders delaminating. I am certain many of you have had similar issues. The original design is less than desired. I have had 2 stainless marine grade shafts fabricated and had the fabricator weld 3/8" threaded stainless rod onto the shafts. I am using Coosa Board for the rudders. I plan to drill 1/2" holes into the Coosa to accept the rods and prefill the holes with epoxy resin and then set in place. The threads and the extra 1/8" of width in the holes with the resin should secure the rods firmly to the new rudder. I have used a similar pattern for the rods taken from the original rudder design, but have extended the 2 larger ones to get them further into the rudder. The Coosa is a non-absorbent material. I also plan to fiberglass the rudders prior to securing them to the new shaft. May even gel coat them. This is where I am at in the build right now. Hope to get them glassed and ready for install soon. ** The Coosa rudders as shown are rough cut*** They still need to be further shaped and fine sanded.

I have actually cut 3 rudders from the 4'x8' -1 inch thick Coosa. I am hoping to pick up a 3rd boat (want spare parts!) for my project of trying to assemble an Ensign presence at my Club on Long Island. (South Shore / Great South Bay) My 2 boats are hopefully going to be incorporated into our sailing Programs this year and I currently looking for a 3rd boat to facilitate some racing.

We have a 2-Ton hoist so we can dry sail boats. Love the lifting eyes!