This client bought a racing trimaran but the rudder was missing. He requested a replacement made to suit and borrowed a sistership boat’s rudder from another owner who also wanted a spare. So we made two rudders at the same time. We contacted the builder for some indication of the build specifications however they never responded so it was decided to make them using Western Red Cedar as the core and laminated with E-glass cloth and epoxy. The layup was a combination of unidirectional and double-bias cloth to allow for the loads. This is a method we have used on many rudders and centreboards with proven results. Templates were made of the borrowed rudder and we offset to allow for the laminate, fairing and painting which determined the size of the core blank. The cedar blank was shaped, glassed and finished within the tolerances of the rudder case which we had for test fitting. The original rudder had composite tubes as the top stoppers with a piece of rope used as the lifting handle. We thought this could be improved on and made a solid composite handle and wide stoppers on each rudder. Once painted we gave the rudders a final test fit before delivery. The new rudders were substantially lighter than the original which were moulded in conventional polyester GRP.






