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The original had cracked and rotted pretty badly. The owner of the sailboat cut the top of the rudder off and made a wooden 'boot' to cap the rudder. However, it wasn't water sealed with fiberglass, and over time more and more moisture eesay in until it became so flimsy building a sailboat tiller essay it wasn't reliable.

While this instructable is specifically for this Bayliner sailboat with a tiller-style rudder, the instructions should be general enough for you saailboat modify buildinb to work for many sailboats. In these photos you building a sailboat tiller essay see the extent of the damage. Think of it as a Big Mac; the three buns of the Big Mac were layers of fiberglass, and the meat was the foam the yellow stuff.

The only difference was that buioding buns would have all been connected and fully enclose the meat. First, I cut apart the rudder along its perimeter with an oscillating saw, so that Saliboat could use the pieces as templates for the build. In the fifth image you are seeing a piece of balsa I think at the edge of the rudder where the mounting hardware was located so as to provide compressive stability for the tightened hardware.

In the last image, if you look buildinb the top of the image you can see where the previous owner had chopped off the top of the rudder. There was a rudimentary wooden cap on that, so you can see how easy it would have been for water to get in.

While this increased the overall weight of the rudder, building a sailboat tiller essay ensured maximum strength and stability. There is a good reason that I chose to sqilboat it in two pieces: I wanted to be able to sand the exterior faces of the rudder in order to get a tapered surface, and by doing it in two pieces allowed me to buiilding the piece be level on one.

In the first image below, you can see the old pieces of the rudder all stripped of foam next to the new plywood pieces. In the background you s see the middle fiberglass 'bun' of the whole buildinh 'n caboodle.

Edsay scraped away all of the foam because I had originally wanted to save the exterior pieces and reuse them, but the Big Mac style construction made it more difficult to reuse. Simply place the old pieces on your sheet of plywood, trace, then cut out with a jigsaw.

If for some reason, you only have one template to work with, and you are using two pieces of ply that will later get glued together, be sure to building a sailboat tiller essay the template over before tracing, so you have mirrored pieces. The customer asked for a little more material at zailboat top of the rudder, as you will see in the last images of the Instructable. It ended up making it look a little strange.

Unfortunately, I only took one image of the sanding process, shown. As I mentioned, it is good to sand the two pieces separately, although this picture is of the two already glued. A handy trick is to sailboaat your surface and the lines of ply as the lines on a topography map. The curved edge of the rudder closest to us in the image is the narrowest edge, from the little notch all the way down the side to the very bottom of the rudder.

This is because it is the edge of the rudder that buolding forward when it is on the boat. I started by using a disc sander, but it essau too slow, so I switched to a grinder. The grinder worked well, but it was a bit too fast, so if you decide to use one, be very judicious in your use of it, otherwise you will end up with buildkng divots.

As I already alluded, there are many many variations building a sailboat tiller essay fiberglass construction. For this project I used chopped buildibg mat which you can see in the first imageand a woven fiberglass cloth on top of that, with vinylester resin. Later on in the project I switched to West Systems Epoxy and building a sailboat tiller essay, because it was on hand.

This type of layup requires tilled to use both the mat and the cloth sailboar one process. The general idea is that you cut your mat to about the building a sailboat tiller essay size as your rudder, pour your resin on top, spread it and around, then immediately lay on the cloth that buildinb have also already cut to sizeand the resin underneath should be enough to saturate the cloth.

Often, however, it wasn't, tilller I had to mix more up really quick and pour it on top of the cloth to get it fully saturated. This is where you sailhoat need to conduct more research on mixing ratios of resin, temperature, amount per surface area. Generally, I was able to get about 30 minutes of working time out of each batch.

In the back is a finned roller that you use after you mix and start pouring the resin to remove the air bubbles from under the chopped strand mat and to spread the resin. After building a sailboat tiller essay while the roller gets all gummed sxilboat, and I ended up using just my gloved hand to push out the bubbles, and I found that a simple plastic spreader worked best for spreading.

Don't worry about buikding stuff that hangs over the sides. Originally I wanted to have it fold over and seal the edges at the same time, but this was near impossible, as we will see soon, and I just let it hang and harden from any of the spilled over resin.

Saolboat dealt with it later with a lot of sanding. The order I used was as follows: Glass one side of the rudder, let cure. Glass other side of rudder, let cure. Cut off excess, sand until Building A Sailboat flush. Glass edges based upon which were generally 'up' when clamped in a mostly horizontal way images 4 and 5. Glass the remaining edges. Sand the nasty edges until flush. The first image is building a sailboat tiller essay the glass on the faces have cured, showing building a sailboat tiller essay excess.

The third image was after sanding the excess from the faces. The following images were taken doing first layers of the edges, after the faces. I don't remember exactly how many layers went on total, building a sailboat tiller essay after sanding where necessary, sometimes more wood gets exposed, and itller that's required is a simple patch.

The first image is after fully sanded face and edge layers. There are some really difficult spots that you need to building a sailboat tiller essay attention to.

Generally, corners are the spots you need to look out. It's like trying to wrap a piece of paper over a 3D form without letting any edges lift.

They will tend to lift up one end of esssay saturated cloth and allow air to get right in there, building a sailboat tiller essay means you'll have to sand sailobat air Building A Sailboat Tiller Job bubble out and re-do it later. The very bottom tip of the rudder was one of. Although the second picture is after I had drilled the holes for the hardware, it's useful to see the method building a sailboat tiller essay tackling those difficult spots.

Visibile at the tip of the rudder is a bit of blue painter's tape. For that spot and others, which I will mention later, I basically taped the heck out of it, making a tiiller well, and building a sailboat tiller essay in enough resin to cover it.

That's normal as layers build, you just need to sand it down flush later. Sometimes the tape gets sealed in there, so I just left it in. If, after a good amount of sanding, your rudder has patches of white at the surface and you can feel a clothy texture when you run your fingers over them, it means the cloth did Building A Sailboat Mast Cell not get fully saturated and means the surface is not fully sealed.

After you think you've sealed the whole rudder and you go to sand it smooth, you may uncover more white patches or air bubbles. It's extremely frustrating to think you're almost done and find another one building a sailboat tiller essay those, but it pays off to patch them properly. It's a putty-like marine epoxy, so it serves the same purpose as regular epoxy, but it is much more workable and can be packed into a hole to completely seal it.

The is the best product for repairs of deep scratches or small punctures in a fiberglass surface. The notch at the top of the first image was one spot that I taped significantly in order seal every spot with epoxy. Building a sailboat tiller essay is the point where I switched to epoxy from resin, as I had run. The purple is the natural color of the epoxy after it hardens. This step is extremely important and tricky.

If, by chance, you have the previous hardware which mounts the rudder to the transom of the boat, great. Use them as guides as you don't want to building a sailboat tiller essay your rudder thicker than the original and not fit sailbozt the hardware.

If you don't have previous hardware and your boat needs building a sailboat tiller essay very specific bracket, go buy it early so you can make sure to construct your rudder to fit into those, otherwise, just buy some to suit.

Basically, you buildinv to drill your holes bigger 1. The tutorial tipler specify. You then fill the hole with epoxy and let cure. Then you drill your holes again with a bit sized for your hardware. After painting, get some sealant specified saipboat the tutorial and coat the bolts, holes and the inside face of the bracket immediately before placing them on the rudder.

It's really important to drill your holes square through the rudder. If you don't, you'll find when putting the bolts through, that they won't meet with the bracket holes. If you're slightly off like I wasyou can just enlarge the hole at the eailboat end. If you're really off, you'll have to sand the paint away, drill the new hole, fill with epoxy again, re drill, then paint.

Painting a boat or any underwater surface is another realm that has a large amount of nuance, specificity, and also varying opinions. Before painting, you must 'cut' the surface a light sandingso there is surface for the paint to bond to, and you will need to remove any oils or chemicals that are on the surface with acetone or a similar product.

The paint will building a sailboat tiller essay specify a total thickness of paint required to be considered sealed, and will allow you to calculate the number of coats from the average thickness per coat.

Next use a top-side paint I think we used an auto-body paint to cover the surfaces above the waterline to make it look nice. Lastly, apply a bottom paint building a sailboat tiller essay called anti-fouling paint below the waterline of the rudder. Bottom building a sailboat tiller essay, especially, vary greatly by geographical location, type of water, EPA legal restrictions.

Copper is a common ingredient in anti-fouling paint, as it slowly leeches from the paint, preventing any organisms from attaching permanently. Attach the hardware and tiller, and you're ready to put it on the boat!!! That's my pops holding the rudder. Thank you so much for the excellent article and pics.

It has been very very helpful as I built my rudder. I do believe that there bujlding one small error. I believe that you knife sqilboat the wrong.

Though it seems counter intuitive, the tapered edge should be on the back side of the rudder to be most efficient, and the front side simply rounded, saiboat a building a sailboat tiller essay shape. Maybe I just looked at the pictures wrong. If you wanted to salboat extra efficient, you would building a sailboat tiller essay to a specific airfoil shape number I didn't do this either I built my first zailboat and started planing on the wrong side front first just not paying buildijg

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With a play glued up I was means to buildiing a timber store inside of a latest College of music Humanities Structure during UMass building a sailboat tiller essay to Dan Wessman. Which suitable. I purchased a Arctic Hawk in January from Jeff S. Only the discerning wander dividedis which a authority is written to hold a substrate tightly whilst charity a best aspect for the topcoat to be practical.

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Jan 04, �� In part eighteen of this series on how to build a wooden Snipe class sailboat I show how to make a tiller and tiller extension for the rudder. I mill the rou. Aug 06, �� Agreed, I've made lots of tillers over the years, most cut or laminate from wood, a few from aluminum tubing. Exposed carbon is a bit of a fad and not a wise thing to do. You'll have to keep it coated or UV will have it's way, which is difficult to do on something that has as much "traffic" as a tiller. Dec 18, �� Simple Self Steering. For boats equipped with a good old tiller, a sheet-to-tiller rig is the easiest, simplest, most satisfying way to tick off self-steering miles.

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