Damaged Rudder: Repair it or Replace it?

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I accidentally damaged my rudder when I hit a buoy on the port side. I was distracted for about 15 seconds, and the current pushed us into it. Fortunately, everyone on board is safe.

I noticed the wheel became extremely tight almost immediately. Using the emergency tiller was also difficult, although the prop and gear are still functional. The inside of the rudder shaft looks fine, with no leaks. I’ve attached some images for reference.

I only have third-party insurance, so I will need to cover the repair costs myself. I plan to do a short haul to assess the damage.

Here are the options I’m considering:

1. Repair the rudder at a marina in the NYC area, with estimated costs ranging from $1,000 to $5,000.
2. Purchase a scrap Nonsuch 26 for $3,000 and use its parts for the repair.

I would appreciate any ideas or advice from the group.

Thanks,
Siva Surendira

‘Inner Peace’ NS26C
Jersey City, NJ

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[system]

Siva,

Ouch!!! Sorry to hear about your problems. Rough start with a new boat.

I’d suggest you see if the INA’s on-retainer advisor and former factory rigger, Mike Quill, has any advice. You can get to him via the www.Nonsuch.org website by opening the MEMBERS tab and clicking on MAINTENANCE.

A third alternative to the two you mentioned is to have a new rudder built. The specs for the rudder are on the www.Nonsuch.org website. Open the MEMBERS tab, click on NONSUCH SHOP DRAWINGS. Open the Nonsuch 26 collection and look for the ones titled, “Nonsuch26WheelSteering,” and “Nonsuch26RudderTop+SideView.”

You’ll also want to look at one drawing from the Nonsuch 30 shop drawings, titled, “N30 Rudder Fabrication.pdf.” That show the interior structure welded to the rudder post that’s sandwiched inside the fiberglass rudder itself. The dimensions of the rudder may be different, but the dimensions of this component of its interior are likely the same.

You can do a web search for outfits which build replacement rudders. The one I’ve heard of, although I have no experience with them myself, is Foss Foam: http://www.fossfoam.com/index.htm

I’m pretty sure there’s enough information in the drawings for them to supply you with a quote.

I don’t know how much a brand new rudder will cost, so I can’t promise that this is a viable alternative. However, if the price turned out to be acceptable to you, that would certainly ensure that you end up with a rudder that has no latent defects.

With the other alternatives, make sure you inspect whatever you get carefully before purchasing. You’ll want to make sure you’re not substituting one bent rudder for another, that there is no water being absorbed into the interior filling (e.g., if a small hole’s drilled near the bottom, does water weep out), and no signs of rust from the interior.

– Bob
Me Gusta
Nonsuch e26U #233
Looking forward to seeing folks in Toronto:
https://nonsuch.org/2024-INA-International-Rendezvous-Status

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As Bob says: “Ouch”. The bend in the shaft is worse than the one I put in mine when I hit a log. You can try having the rudder post straightened but I suspect they won’t be able to fully straighten it and if it is not straight it will likely bind making the steering stiff. Mine rudder shaft was bent backwards just where it enters the rudder proper.

I had my rudder rebuilt. They split the blade, cut the tabs off and had a new shaft machined. The original tabs were welded to the shaft. Some new foam put in and the blade re glassed around the new shaft. The biggest delay was waiting for the machine shop to fabricate the post (four weeks). You will want to check the gussets/knee braces around the rudder shaft, the top bearing, the quadrant and steering cables for damage. The rudder is heavy so a fork lift was used to move it around. The boat yard lot was level and paved so the boat was lifted by the travel lift to get it high enough to remove and reinstall the rudder.

The fix was covered by my insurance. The repair bill included 48 hours for labour. I suspect by the time the dust settles the cost to repair the rudder properly will be closer to the $5,000 then $1,000.00.

Mark Powers

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[user43]

“Ouch” seems to be the word of the day. Sorry about this “event”. I would not buy a scrapped Nonsuch as you have no idea of what the rudder is really like (and it could have all kinds of issues like water in it, shaft bends or rot or corrosion inside of it, etc.

I’d get a few quotes to rebuild your rudder from reputable places. I have heard of Foss foam. There is also an outfit called Ruddercraft. Depending on the cost of the rebuild and all of the associated costs, I’d also get a for a new one. Sorry but I think that you’ll be very lucky if you can get away with $5 K to fix this.

Good luck.

Ernie A. in Toronto

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Thanks Bob, Mark, Ernie.

I spoke to Don at Fossfoam. The estimate is $2000 + $200 for shipping, and once the order is placed, it will take 2 weeks to deliver. This seems to be the option other than using a sledge hammer to straighten the rudder shaft.

-Siva

[user43]

That’s a good price from a good outfit.

Ernie A. in Toronto

[system]

It sounds like the rudder replacement is the way to go.

Although the sledgehammer plan might be more cathartic…

– Bob
Me Gusta
Nonsuch e26U #233
Looking forward to seeing folks in Toronto:
https://nonsuch.org/2024-INA-International-Rendezvous-Status

[system]

So sorry that this happened. Good to hear you made it back without injury.

When you do the short haul, make sure you have the right folks on hand to thoroughly evaluate the condition of the entire steering assembly.

The forces necessary to put the kind of bend in the rudder shaft may have caused deformation of other parts that will make removal of the old and installation of the new rudder tricky.

Would be good to be ready to drop the new rudder in as soon as it arrives.

It might be worth looking at what it would cost to put the boat on the hard till it’s been repaired. There is a small chance that a leak could develop…you can rest easy if it’s not in the water, plus and other repairs can be done without the pressure of a deadline.

The yard might give you a good deal on storage if they know they are going to be doing the install and any repair work.

I hope the repairs go smoothly and that no other damage is found when you get a closer look.

Rob Cohen
s/v SOAVE
NS33 #009
Westport, CT

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Thanks Rob.

Here is the action plan.

1. So a short haul to inspect the damage (there are no leaks inside the hull as of now)
2. Get an estimate from the Marina folks for the repair (which I believe would be about $2000 at LLM)
3. Either order a $2200 new rudder from FossFoam or get a $200 rudder from a 1984 NS26C I found

-Siva

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Siva,
Thanks for sharing the plan. Hearing how others address repairs is helpful when it’s our turn… I guess you already know the value of such open dialog due to your interest in AI.

Best to you… hoping for a speedy recovery for Inner Peace.

Rob Cohen
s/v SOAVE
NS33 #009
Westport, CT

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Thanks Rob. The more data we share, the better the AI gets.

[Val_Aries]

Personally, I would definitely give the $200 rudder a shot. They are really sturdily built… must have been a hell of an impact! It should be pretty obvious whether or not it has water damage. Just make sure the shaft looks straight. At least that’s how I would handle it.

[system]

Thanks Val. Below is the boat I found in Wilson, NY. Its available for parts. The guy told me if I could come and inspect. I live 10 hours away, so I asked him to see if he can check it. The rudder looks fine though.

If anyone in the community lives near Wilson, NY and if they can inspect the rudder, it would be of awesome help.

Thanks,
Siva Surendira

‘Inner Peace’ NS26C
Jersey City, NJ

[Val_Aries]

The reason why he is parting it out would be helpful in determining whether or not the rudder is in decent/salvageable condition.

(attachments)

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The boat had an engine fire last season. So the engine is out. The wishbone, winches, and other interior parts are in good shape.

Thanks,
Siva Surendira

‘Inner Peace’ NS26C
Jersey City, NJ

[system]

What a shame that he’s parting it out. It sounds like a good candidate for an electric conversion.

[system]

Siva,

Do you know the name of the boat and the HIN ? INA maintains a registry of all the Nonsuch boats and it be good to know to update the registry that this boat is out of commission.

Don

’87 NS30U #369 - Breezin’

Vancouver, BC

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Not now. But will inquire and let you know Don.

Thanks,
Siva Surendira

‘Inner Peace’ NS26C
Jersey City, NJ