‘Blue Seiche’ Rudder Repair,
Winter ‘05/’06
By Jay Grizzell
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One typical problem of living in a climate such as Chicago is having to deal with freezing temperatures. As water
freezes, it expands. Water trapped inside of rudders freeze, and expand from the inside out, thus delaminating and/or
cracking the inside of the rudder.  This action forces people such as Jay to repair, if not replace the rudder. The
following article details how Jay economically repairs his rudder. This is a great winter project you can do in the
privacy of your own garage.  -- Steve Prusinski
The ‘Tapping w/ Large Washer Technique’
revealed the extent of delamination to the
port side of rudder.  Starboard had no
evidence of delamination; go figure.  Holes
drilled and router-line are evidence of
experiments to establish “Best Removal
Procedure”; still looking for that solution.
Five profile templates were made (4 shown)
to help re-create the Foss Foam “As Built”
condition. Profiles were used as ‘bread
crumbs’ to return to the beginning.  Very
helpful as process unfolded.
The skin has been cut and peeled away,
exposing a dry foam core (a good thing!)
with a few voids/depressions/craters.  
The surface has been epoxied and
sanded flush, ready for re-glassing (mat
base and 2 layers of woven mat).  Black
markers assisted in indexing of
cardboard profile(s).
A "peanut butter" consistency of West
System w/ filler was critical for initial
two lifts. Run-off of viscous material
would have been a nightmare and a
waste of good epoxy!
Initially, high spots are sanded smooth
(very few) after 3rd lift of epoxy.  Getting
closer (but still very far away)…
After four to five additional skim coats in
localized areas, a lot of sanding and
questioning whether this would EVER end, it’s
ready for barrier coat, Interprotect 2000.  

Procedure for each of the six coats:
  1. Surface washed w/ soap & water rinse
  2. wet-scrub w/ Scotch pad
  3. Clean w/ Solvent Wash
  4. Wipe with dry cloth  
  5. Roll on of Barrier Coat
  6. Repeat entire process 24 hours later
    (next evening)

The rudder was hung from ceiling/floor joists to
permit access to both sides, top and bottom
without having to re-adjust; the rudder is more
awkward than heavy (required teenage help to
lift into position).  
Darn smooth result w/ final profile equal to Foss
OEM.  Ready for VC-17.  The house smelled awful
during this process; windows & doors were opened
(freezing temps outside) w/ fans blowing.  A heated
shop would’ve been great.
Voila!  If only the weather would cooperate, this
would be out of the garage and hung under the
stern.  Glad it’s completed; hope it’s not repeated
under my stewardship.  Lots of help from the
crew @ the North Avenue West Marine in
Chicago.
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