Hi Randy
Great to hear you are in the water and it’s all put together.
I don’t wish to pry but I would like to know what “1&1/2 inch void between the tapered portion of the tube and the bottom of the hull” means. Do you have a photo before all was glassed in perhaps?
Thanks for the photos. First time I have see a photo of the rudder tube.
Could you guess how much the rudder weighed? I want to drop mine soon and I’d like to be prepared.
As everyone seems to have this problem with leaking rudder gussets at one time or another I suspect this is more sloppy manufacturing rather than a one off manufacturing “defect”.
Maybe because installing the rudder and keel were one of the last things done on the boat? The deck had to be on before the rudder tube was glassed/installed maybe and glassing the gussets and tube in were awkward inside there through the hatches. This might explain why they were done so poorly.
The leaking rudder gussets is more of a design issue than a manufacturing issue. When the prototype of the Nonuch 26 (Mascouche) went out for her first trial sail, she took Ed Botterell and George Hinterholler on a wild ride up and down the Niagara River in a blustery breeze. Her antics scared the wits out of the US Coast Guard. George was furious and ordered a much larger rudder. (This was passed on to me by Botts) This became the production rudder that does the job of controlling the boat in a breeze at the cost of a substantial weather helm (and helmsman’s strength) which exerts great pressure on the base of the rudder tube when the boat is not reefed in breezes of 15 knots plus. It might have been a better solution to reduce the foot of the sail to keep it nearer the centre of effort, but that would have meant ordering new sails for Mascouche and any production boats under construction in addition to redesigning the wishboom.
There was obvious pressure to get the test sails done and production under way. When I bought Mascouche in 2006, she was equipped with a small prop designed for a gas engine and not a Universal 16 diesel with maximum of 2,800 rpm. She could only do 4 knots with the engine flat out and even then failed to reach operating temp. That winter I ordered a 3 bladed slipstream prop from SeaHawk in Australia. They matched the engine perfectly. Now she warms up promptly and delivers 4.5 to 5 knots at 2,000 rpm. I guess that George used the small prop since it was all that was available at the time she was launched in 1981.( diesels were few on the Great Lakes then) Peter Pangman who bought her from George loved racing and was willing to sacrifice performance under power for getting the edge under sail so did not replace the small Flex-O-Fold for something more appropriate. The 3 blade Slipstream has proved not to impare Mascouche’s performance under sail.
One of the reasons I changed the rig was to achieve better balance. The foot of my sail measures 15.5’ compared to 20’ of the standard rig. There is far less strain on the rudder in a blow and less chance of getting in irons when steerage way is lost. With the new sail plan one could consider reducing the size of the rudder. It does not need to be as big. I will leave that for somebody else to do.
Thanks for your thoughtful reply and explanation about the design compromise leading to the Nonsuch 26 rudder. In an earlier message to me you mentioned reefing early and it will not hurt speed but will lessen weather helm. I followed your advice and now reef much earlier than in the past. Sailing is more enjoyable and I think just about as fast with a reefed sail.