Rudder Materials & Construction

The area of the Help & Advice forums where requests for help about the centreboard & rudder of an Osprey can be posted. Additionally, if owners or others have hints and tips that might be of benefit to others they can be posted in the forum as well.
No Idea

Re: Rudder Materials & Construction

Post by No Idea »

Forgot to include a pic of the careful quality control assessment of the laminated ply resistance to bending and elasticity.
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No Idea

Re: Rudder Materials & Construction

Post by No Idea »

Spent some time looking at my router and thinking that it would probably do a better job of cutting out the rudder blade than my plane.

Decided I needed to suspend the router over my bench and push the blade under it so it would cut it straight.

Well, it sounded right in theory anyway.
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Decided to use the router upside down to cut my template out.

Not sure this was a smart idea as it tried to stab me with it.

Several times.
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No Idea

Re: Rudder Materials & Construction

Post by No Idea »

Well....

I set the router height off the bench using my template.
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So far so good...

First few cuts were fine, but then it started cutting too deep.

Took me far too long to work out that I was getting a layer of sawdust under the blade and this was lifting it up.

The result wasnt quite what I had in mind.
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Ho Hum, back to the drawing board.

Next time I must remember not to machine wood in the kitchen. The mess was baaaad.
No Idea

Re: Rudder Materials & Construction

Post by No Idea »

Take Two.....

I cut some new bits of 9mm marine ply while my oldest wasnt looking
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I sanded the grain to open it so the resin would stick
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I resin coated it so the next coat, the microfibres in resin, wouldnt get too dry as the wood wicks away some resin.
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I mixed the microfibres into the remaining resin and coated the boards.
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No Idea

Re: Rudder Materials & Construction

Post by No Idea »

I am going to screw it together this time
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And clamp it
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And not put it on a radiator to cure.

Its done.

Ive just ground the edges off to make it square and marked on where I need to cut the top.
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I found the pattern I made from a profile prog on my computer and glued to a piece of wood
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No Idea

Re: Rudder Materials & Construction

Post by No Idea »

I put the old rudder on top and marked out the shape of the piece that goes into the rudder stock.

I turned it far enough that this board will go upright.

I cut it out.
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I ground out the shape of the first curve and discovered a gap in one of the plywood sheets.

Luckily its running up the board so I can fill it.

Had it been accross and near the bottom of the rudder stock, I would have had to scrap this one too.
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Thats the second curve ground out
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Thats the first on the second side.

I am not too worried about neat at this stage, only that its close to shape and I dont undercut it.
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No Idea

Re: Rudder Materials & Construction

Post by No Idea »

All four curves ground out
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Thats the first side sanded.
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And the other side
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Looking at the stock and seeing what I will have to do to fit it.
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No Idea

Re: Rudder Materials & Construction

Post by No Idea »

Time to give it a coat of resin to seal the grain
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and a layer of tape along the leading edge
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Viola
Posts: 235
Joined: Mon Jun 23, 2008 10:40 am
Your known name (real identity): Viola Scott
Your family name (real identity): Viola Scott
Sail Number: 1314
County or State or Province: Scottish Borders
Country: UK
Your principle sailing club: Kielder Water Sailing Club

Re: Rudder Materials & Construction

Post by Viola »

Looking good!

Viola
No Idea

Re: Rudder Materials & Construction

Post by No Idea »

I need to make another spacer for the stock as the new blade is thicker.

I didnt have any ply the right thickness, so I ground two plies off a piece to get it right.
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There is enough space left to use a couple of pieces of plastic milk bottle or ice cream carton lid to make a bearing surface for it to pivot up and down
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Need to fibreglass it together and then go get some new bolts as the old ones are now too short.
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