Bent Rudder Stock

Date: January 31 2001
From: Gene Rohloff gener@execpc.com

Last fall I ran aground on the Racine Reef and bent my rudder post. In the process of removing the rudder I was astounded at how heavy the rudder was and wondered why so much weight was located so far in the stern. All messages I've received have been negative relative to that project. As a result, I've abandoned the idea of lightening the rudder by drilling out plugs and filling the cavities made with a lighter material.

My urgent project now is to try to either straighten the post, remove the old post from the rudder and instal a new and straight post, or find a replacement. If you know of a spare rudder for a '78 Endeavour 32 let me know. Thanks for your interest,

Date: February 3, 2001
From: Mike Miller capnmike_s@yahoo.com

I don't know what the name of the guy is, but there's a fellow in Florida who made all the rudders for Endeavour---they didn't make their own. When mine was broken in half after Hurricane Bob, the marina that did my repairs, Tripps in Westport Mass., called him and he made a brand-new one and had it shipped to Massachusetts very quickly. Tripps Marina handled the arrangements and they may know who the guy is...apparently he has molds for many different boats' rudders, and specializes in that. Hope this helps.

PS. If you replace a rudder post, make sure you check or replace the upper bushing too...We neglected this little detail, and soon regretted it as the rudder post was loose and caused problems...off the coast of South America!

Date: February 4, 2001
From: Kevin Coon kkcoon@worldnet.att.net

Since it is a solid rudder shaft: I would straighten it out and use it if the shaft wasn't bent too far, and I could straighten it. The post has protrusions that extend into the rudder, so , removing the shaft from the rudder would destroy the rudder. A good yard could fabricate a new rudder and shaft for you, using the old one as a template. It would be a fun project to do yourself if you like that kind of stuff.

Have fun!

Date: February 9, 2001
From: Paul Uhl endvr32@endeavourowners.com

Here's the contact info for the guy who made/makes the Endeavour rudders:

A gentleman by the name of Chuck Foss developed a high density foam, and with it in the 1960's, started FOSS FOAM PRODUCTS. In 1978 Bob Walker (Al's son), who up until then worked for a company next door to FOSS, helped move FOSS to Clearwater, Florida. Once set up in Florida Bob began soliciting contracts from boat manufacturer's to build their rudders by going door to door with a sample rudder and letting people try to destroy it with a sledge hammer. Apparently it was a very convincing demonstration.

Before the FOSS process hit the scene rudders were typically manufactured using a resin and filler material in which the two halves of the rudder were first manufactured. Once the halves were made they were then sandwiched together with the SS rudder stock and its blades using more of this resin/filler material to effectively "glue" all the pieces together. The problem with this process was that because large quantities of this material were used, it was susceptible to cracking and splitting. This would of course allow water in and begin the deterioration process. Also, because water got inside all the metal rudder components had to be stainless steel so that it wouldn't deteriorate as well.

According to FOSS the advantage to their process was that their rudders were lighter, were very strong, weren't susceptible to the water migration issues, and were much less expensive. They also use a solid plate with a continuous weld rather than separate blades inside the rudder.

Anyway, Endeavour gave the contract to FOSS to build the rudders for the 32, 33, 35, 37, 38, 40, 42, and 43. They still have all the molds for the Endeavour rudders and build replacements for them. They also build rudders for many other boat manufacturer's

One note. He said that he doesn't recommend straightening a bent SS rudder post (cold rebend) as the SS looses 40-60% of it's strength.

Date: February 7, 2001
From: Don Shepard stoneware@journey.com

So did Endeavour start using this type of material in 78 and newer and they must have had some poor stainless or used steel in some of the rudders because I had rust stains coming threw my rudder. Edward's of S-2 design used this style of rudder on the S-2 boats. What's the thoughts here. I drilled holes in the bottom of my rudder and let the moisture escape threw out the hard season. Then I filled the holes and the bolts that hold the rudder at the bottom of the skig with 5200 and the entrance of the post at top of rudder. than put a barrier coat. Than interlux 2 part epoxy paint then bottom paint and that has helped eliminate the staining.

Date: February 8, 2001
From: Paul Uhl endvr32@endeavourowners.com

It's very probable as Endeavour made some big design changes to the E32 around that time. In fact the sail plan for our 1982 boat is dated 8/79 (signed by Bob Johnson) so I would assume this about the time they made the final design changes to the boat. There was most likely another 'major' shift when they eliminated the centerboard in 1977 but that would have been prior to FOSS moving to Florida.

Al was very helpful so you might want to e-mail him. His dad is still around and may be a great resource.

Date: February 7, 2001
From: Tom Berardinalli coolchange@mediaone.net

I have a 1977 E-32,I noticed rust comming out of the top of my rudder where the post is,after a couple of months out of the water. After reading about its construction, I drilled a few 3/8 inch holes into both sides, middle and bottom area, this allowed moisture to weep out for a few days. After it stoped and seemed to be dry, I poked into the holes with a wire and all sorts of gritty matierial came out.When that stuff dried it felt and looked like rust.I ended up blowing air in one hole and all (I think)the loose stuff came out another.When I figured it was dry inside,I pumped a mixture of West Sys. and filler into the lowest drill hole untill it came out the top.I patched and painted it seemed good and solid.That was last Spring.I hauled out in Oct.and there is just a tiny bit of what appears it be rust out of the top of the rudder.I really don't know what else to do about it,short of replacing it.So any hepful tips or remedies would be greatfully appreciated.

Date: February 8, 2001
From: Don Shepard stoneware@journey.com

We have a 79 and it has the form core rudder. There is a 77 on the hard just 5 boats down from ours and his rudder looks different than ours. Ours looks bigger I think what I will do the next time I am at the boat I will take the rule with me and measure his rudder. I know that the inside of ours he said looks just like his other than they took out the oven and put a microwave in it's place. But the wiring for the mast and plumbing is a little different for the head. I think I will e-mail the fellow and find out more on the rudder and let you know what he has to say. G'day

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