Rudder cheek worn

[Dirck Tromp]

I'm replacing my rudder, and I noticed that the aluminum rudder cheek holes are worn out of round. Also slightly corroded. Is it time to replace?

 

[sailcraftri]

Before spending the $75 plus for a new rudder cheek I would repair this one. Sand the rudder cheek, fill the holes with JB Weld for metal, sand smooth, re drill the holes. Then I would prime (aluminum primer) and paint. That helps prevent future corrosion. Other option is to get a fabricator to wels some new aluminum donuts onto the cheek. You could also try JB Weld and glue on stainless steel washers.

 

[Dirck Tromp]

Thanks sailcraftri. I live in Saudi Arabia, and things like JB weld can be hard to find. But find it I did! I'm heading to the garage now to sand and weld. I'll post pics of the results.

 

[fhhuber]

another option on the hole is drill up a size and then insert very short brass tube to bring it back to round and the correct size.

It has to get worn just about to where the nut slides through before you can't fix it without welding. And then there are professionals who can weld it. (special techniques for cast aluminum)

 

[Webfoot1]

Machine shop should be able to Tig weld the holes shut and re drill for about $25 or less. Easy
way would be just go with the next size up bolt. A Metric bolt may be just big enough to get away
with just cleaning up the hole. Install a brass bushing in the rudder to keep the rudder from cracking
and the hole from enlarging.

Aluminium has what is called "sacrificial corrosion." This means
the corrosion on the outside surface keeps the aluminium under it from corroding. You can clean it
up if you wish but it will be just fine as-is.

I've never had a plastic rudder cheek and suspect they will never last as long as the Aluminium ones. I've
got two that have been around since the early 1970's.

 

[beldar boathead]

Honestly, is this even worth dealing with? The slightly enlarged hole won't have any impact on sailing the boat. BB

 

[Alan S. Glos]

Plan "B". Get a stainless steel bolt one size larger and drill a corresponding hole in the cheeks and the rudder head. Insert bolt and you are good to go. 5 minute, $1.15 fix.

Alan Glos
Cazenovia, NY

 

[Webfoot1]

Anyone think to ask him if he's doing salt-water sailing. Less than fantastic plastic rudder cheek
might be a better choice for such.

 

[Dirck Tromp]

Thanks all for the helpful replies. I sail in a hyper-saline bay in the Arabian (Persian) Gulf. The inside of the cheek is heavily pitted/worn as well. I'm trying the JB weld method, but when I go back to the States in December I will bring back a plastic cheek. The boat has been sailing the same bay off and on for almost 40 years, so the cast aluminum is quite durable!

It is very difficult to find specialist welders here, especially since I don't speak Arabic.

 

[L&VW]

Plan "B". Get a stainless steel bolt one size larger and drill a corresponding hole in the cheeks and the rudder head. Insert bolt and you are good to go. 5 minute, $1.15 fix. Alan Glos
Cazenovia, NY

That's exactly what I'd planned on suggesting. But I've never experienced a 5 minute repair: there's always something that goes wrong!

another option on the hole is drill up a size and then insert very short brass tube to bring it back to round and the correct size. It has to get worn just about to where the nut slides through before you can't fix it without welding. And then there are professionals who can weld it. (special techniques for cast aluminum)

Now That we now know of the "hyper-saline" sailing environment, attaching small zinc anodes would be my next move.

$5 at WalMart—cut in half:

 

[signal charlie]

I'd go with Alan's plan.

Dirck did you get the inspection ports we sent at the end of May. The shipping wasn't much, so maybe you could get a replacement rudder cheek as well?

Cheers
Kent

 

[Dirck Tromp]

No Pics, but JB Weld did the trick. Now with a proper length tiller, a new rudder, and tight connections the boat handles and maintains course so much better. First races for me yesterday resulted in a 3rd place overall finish in the Novice class. I'm totally hooked! Thanks gurus!!