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I am new to this group and am considering purchasing a DE32. The many topics on this site have been very helpful in learning about the DE. I am wondering how big a problem the rudder has if there are rust spots on the outside indicating water intrusion and corrision inside? I am hoping it is not a total rebuild problem. Thanks! Terry
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I would consider that you would need to take the whole thing apart and inspect it at the least. I have only heard of one boat a DE45 having major rudder issues, but they had to rebuild theirs. So I think it is uncommon but sadly not unknown.
I would get a survey that notes that there are issues there and use that to either get them to fix it up front or to reduce the asking price by the cost of getting it fixed/replaced if you intend to go farther with this boat.
At our last haulout we had the rudder ground down and recovered in about 20 oz of fiberglass with west system epoxy. The interior seemed to be a stiff foam core that was covered with fiberglass. We did not remove any core material to look at the stainless grid underneath the foam.
I can't remember if anyone has documented a rudder project on the site.. ahh I did find one so here you go
/info-index/boat-hull-and-deck/rudder-removal
anyways welcome to the group and good luck with your search for a boat I hope it ends up being a DE 🙂 they are great boats
scott
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Thanks Scott for your reply and all you great work with this site. I did read the post about the rudder rebuild and was hoping that I did not have to go to that extreme. I would feel better if the rudder were stripped and inspected, expecially while navigating in bad weather. Think we are going ahead with the survey, though. See what the surveyor says. Boat does need allot of attention and TLC.
Is it necessay on DEs to add a layer of fiberglass to the rudder like you did to yours?
Thanks again,
Terry
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I would not say that it is a normal thing to do. When we hauled out the only blisters we found were on our ruder and we had a few stress cracks in it. I didn't see any rust and didn't want to tear it apart and the yard offered a 300 dollar materials and labor deal of grinding the rudder and some bad areas in the fairing around the rudder shoe on the keel down and re-doing them with glass and epoxy. It would have cost me almost 300 just just to buy the materials so I got them to go ahead and do it. they ground the glass mostly off the rudder and affected areas of the bronze keel shoe and then we let it dry out for a few days.Then they fared, wrapped and fared again, the keel and then the shoe on the keel. Did a nice job. I have pictures of it in different stages but havent had time to do a write up and post them. sometime in the next year or so I have about 30 projects to document online that I have pictures for.
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Scott,I don't if you remember us from three years ago but we lost our rudder on our DE41 completely off Bodega bay in a storm. I would just like to say that our problems was that there had been some corrosion on the rudder post between the top of the rudder and the bottom of the hull. I don't know about the other Downeasters out there,buy the space between the top of the rudder and the hull was only about 1/8 to 1/4 inch. The area where the rudder post was corroded could not be seen unless the rudder shoe is removed and the rudder post dropped a bit (a foot would be more than enough). This may sound a bit expensive,but because the insurance company said that corrosion was seen,the policy didn't cover it. Given the choice…the cost of removing the shoe or replacing the rudder and post..not to mention trying to get back to shore (under control)…well our costs for the rudder,post,and labour hit pretty close to $12,000 . Just saying…our surveyor didn't catch it either.
Bob Martin
S/V Mariposa Bella
currently in Mexico
PS The new rudder was made about 10% larger than the original and I have to say she handles a lot better than she did.
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I do remember.. Sorry that it cost so much to get the rudder replaced. How much was material costs vs labor costs? Did you take pictures of the build process and layout? We would absolutely love to see how your rebuilt it. I don't think we have anyone else that has said they have done that yet. Hmm.. not sure, might have a DE45 also that has had issues. 🙂 that might be you that I remember talking to... Actually It was you 🙂 So no DE45 rudder rebuild.
I hope like hell that I never have to do that. If so I think I will just build one out of steel. I know a fairy easy method to construct a rudder that way now since I last talked to you. Maybe a couple days and hopefully only 500 dollars of materials or so. Hmm then a lot of epoxy to paint the steel 🙂 lol.
I hadn't thought about this recently but there is a boat building method called origami boat building that uses steel. Go to the origamiboatbuilding group on yahoo and you can get a dvd and book from members there that one of the things it talks about and shows is how to build an outboard rudder out of steel. Basic welding skills and very easy to do. However It should be relatively easy to adapt to a inboard rudder like the DE's
brent swain sells the boot. He came up or refined this boat building method and alex ? can't remember the last name offhand did a dvd video of building the hull of on of brents boats and it includes video of the construction of the rudder.
scott
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We are still considering the DE32 for purchase. Found Bob's post really interesting. Makes me, for sure, want to disassemble the rudder unit for inspection. Wonder if the SS used was of poor quality or if Bob's experience was because of an anomoly in that paticular area of the post. In looking more at the rudder on our possible DE32, I am sure wondering what is going on inside the assembly to cuase slits of rust to appear on the sides of the FG. Thanks, Terry
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