Rudder rebuild advice???

[Benlieb]

Anyone had experience rebuilding a rudder? Shaft got electrolysised.... Cut it out and made a new shaft, should I fiberglass it into the old foam rudder or make a new rudder blade?... Anyone done this?

[tartansailor]

Yes, been there and done that.
I don't know what model boat you are considering, but on a Cape Dory 25,
and most others I suppose; a weak link is the original rudder design.
Mine had 4 pins welded perpendicular to the shaft, and a fiberglass lay up for the blade.
Now consider this a glove on one's hand. With enough stress the "glove"
is going to fall off, and that is exactly has happened to quite a few rudders on this forum.
In my case I had 3/16 sheet SS cut to the exact blade profile and welded to it's shaft;
then filled in a proper thickness profile with fiberglass.
Now if your shaft and pins are in satisfactory condition, don't cut the pins off. Rather weld
a connecting SS rod to all of the pins tips then bend the ends around and weld the ends
of the rod to your shaft. Fill in the space and form your profile with fiberglass.
That rod will insure the integrity of the rudder.
It is critical that you engage a welder that is long experienced and proficient in welding SS.
Dick