New Rudders
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.
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.W e 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 9, 2001
From: Paul Uhl endvr32@endeavourowners.com
Here's the contact info for the guy who made/makes the Endeavour rudders:
Foss Foam Products of FL Inc
Clearwater, FL 33762
(727) 571-3626
www.newrudders.com
Talk to Al Walker
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.
Hope this is helpful.
