Hi Peter,
After a couple of seasons of sanding and varnishing my OEM wooden rudderhead, I finally decided wood was a poor choice of material for the application. I purchased a block of 1-1/2" thick uv stabilized ultra high molecular weight polyethylene. I used the old rudder head for a template and cut the new rudder head from the plastic block with a band saw. Drill a few holes for the various fittings, a little sanding, and viola; a new no maintenance black plastic rudder head! The 1-1/2" thickness was just perfect for the tiller, the pintels, and the two aluminum plates that serve as the pivot point for the rudder blade and keep it from wobbling. The rudder head needs no internal structure, it just needs to be the right shape & size & rigid. I did this project on a Saturday afternoon in 1990. The only maintenance it's needed since then is a quick wipe down with a damp rag.
Roger Pihlaja
S/V Dynamic Equilibrium
1978 Sanford, MI
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