Join the discussion 11 Comments

  • mike givens says:

    Can’t wait to see the next video! My gelcoat came out fairly good for the first time. Thanks to you.
    Hint, For rounded edges cover the gelcoat tightly with waxed paper to form the round edge. Peel it off when it hardens.
    Thanks for giving me the confidence to try it.

  • Dave says:

    It is amazing what boat builders will send out the door for a consumer to buy. Keep the videos coming, they are fun to watch.

  • Chris Flewitt says:


    Can you hurry along with part 3 please! I’m rebuilding a ruddeer for my contessa 28 in England that has the excact same problems only mabe a little worse. The perimeter appears very solid, so I’m hope your method of repair is going to work for me.

    Cheers Chris

    • ~Andy says:

      Hey Chris,

      I’m hurrying ๐Ÿ™‚ I’m swamped with work which has to take priority (it’s what pays the bills) but I’m hoping to have the next vid out before the end of the month…


  • Jim Brinkman says:

    Thanks for sharing. I have a 81 Hunter 22 swing keel that I may fabricate with foam filled fiberglass instead of purchasing due to cost factor, approximatley $1100. I don’t have the old one but a good fellow was kind enough to post measurements of his. I will have to make a mold of some sort. Any input would be greatly appreciated.

    • ~Andy says:

      Hi Jim,

      I hate to say it but by the time you make the mold and rudder you’re going to think that the cost of purchasing a rudder was a deal ๐Ÿ™‚ You’ll have more than half the cost in materials (presuming you are able to get the shape and size correct on the first try) and a couple weeks of labor into it. Personally I think you’ll be money ahead to save a bit longer and buy it ๐Ÿ™ If you’re confident in being able to build it, I’ll try and offer suggestions. Can you forward me a copy of the design / measurements?

  • dave says:

    See how the rudder tube is bonded to the port side rudder skin? Were you able to tell that by the sound, or by asking the manufacture? Or did you just choose to slice off the starboard side and it happened to be the correct side? haha

    • ~Andy says:

      That was all luck ๐Ÿ˜‰ Actually I sounded each side and opened up the side that sounded the most hollow… Just happened to be the right choice!

  • John says:

    Hi, in the process of doing an Catalina 30 Rudder was a bit more difficult to get the foam out of but water was getting on around where the post goes into the rudder. Looks like the foam was put in in two halves and then glassed. took about 16 hours to clean the foam out. Just wanted to share this. thanks for all the info,

    • ~Andy says:

      Thanks for sharing John! I’ve been having server issues and have not been able to log into my website and reply to comments :-/ Think I have that resolved now! I see it’s been a while since you posted this question, how is the re-build going? When you have a chance please let me know!

      Thank you!

  • John Beck says:

    Andy, finally finishing my rudder and noticed there is a slight curve in the rear of the rudder from the middle down. Is this a concern or is there anything I can do about it? When I was filling with foam the back side of the rudder dimpled, I assume from the hea, t Ithink that may be the cause. I had to fair the rudder on both sides to get the belly shape back. Thanks for any assistance, John

Leave a Reply