Repairing a cracked sunfish sailing dinghy rudder - Part 2: epoxy finishing

Don't miss part 1 here: • Repairing a cracked su...
In this 2nd part I apply more layers of epoxy resin over the fiberglass layers to smooth out the weave and fill in some holes/notches to get it ready for varnish (UV protection for the epoxy).
Next up: In part 3 I'll show the varnishing steps...
• Repairing a cracked su...

[@alcourtines4707]

Use a drill press to open up the holes. You just egged them out with the hand drill. Fiberglas is not necessary, just more work. I reinforce the “split line” with 3/8” internal dowels. Better than new. If I want to take the time, I apply 2 part aircraft epoxy/polyurethane. Last time you’ll do it. 53 yrs experience with the Sunfish, 33 yrs teaching wood shop.

[@SimplifySailing]

Great job Jay. How has this repair lasted? I have a Sirius 21 rudder that needs help. I've considered wrapping it as well but wondered if water did get in to the mahogany if it would dry. My boat is in the water 3-4 months a year.

[@summetj]

Doing fine so far, but it's only in the water when sailing. If you do the final epoxy coats correctly and don't sand all the way through them there should be no way water could get in.

[@robertmcglinchey3347]

Part 1/2 are excellent. I assume that I can use the same technique on my laser center board and runner. Both are mahogany. An expert told me I could use Bondo to fill in some small gaps in the bottom of the center board. This is my first time at using epoxy and fiberglass tape.