Here we still are, hauled out at Medana Bay Marina, trying to overcome the most challenging sailboat repair we’ve ever dealt with.
In the previous video we began the frustrating task of sorting out our steering issue, which we believed was being caused by the rudder. The only way to be sure was to take the rudder off and check…
We threw fire and hammers at the recalcitrant skeg and rudder, but still nothing would budge…
Finally, there was an enormous bang-clatter-wallop which got Liz out of her stupor below decks (it’s hot on the hard in Indonesia). She came running up to find out what the disastrous noise meant and was greeted by Hendro, our favourite mechanic.
“The rudder is broken,” he said, half smiling.
The Indonesian way is never to look upset or worried, people tend to be phlegmatic in this country. Liz thought this could mean anything…
Finally Free! Conquering the Stubborn Rudder
For what felt like an eternity, we’ve been locked in a battle with our boat’s rudder. Two long months of pushing, pulling, and trying every trick in the book left us feeling defeated. But this week, everything changed. We finally had a breakthrough, and the feeling of relief is indescribable.
The Power of Heat
After trying countless other methods, we took some advice and brought out the big guns: a blowtorch. The idea was to heat the bronze casting to expand it just enough to break it free. We heated it until it was scorching hot and then gave it a few solid strikes with a hammer. At first, there was just a tiny, almost imperceptible bit of movement, but it was enough. It was the glimmer of hope we desperately needed.
A Successful, Yet Messy, Removal
With renewed determination, we continued the process of heating and hammering. After hours of painstaking work, there was a loud bang and a clatter—the sound of victory! The rudder was finally free.
However, the intense heat had an unintended consequence. The fiberglass around the bronze casting had disintegrated, creating a gooey mess that was clogging up the space and making the final removal difficult. Despite the setback, we managed to get it out. Seeing the rudder detached from the boat for the first time in over a decade was a truly joyous moment. We had been feeling so depressed about this job, and finally having it done felt like a massive step forward.
Assessing and Repairing the Damage
With the rudder off, we could get a clear view of what we were dealing with. The fibreglass fin that fits into the casting was, as expected, in rough shape from the heat. The first step in the repair process was to start rebuilding this section.
I also took a look at the sacrificial teak shoe that sits at the bottom of the rudder. Surprisingly, it had some woodworm damage, which must have occurred long before we owned the boat, as it had been sealed in fibreglass and epoxy for years. Instead of replacing it, I decided to repair it.
The Slow Process of Rebuilding
The next phase of this project is all about patience and precision. We’ve started the process of rebuilding the damaged fibreglass on the skeg. This involves carefully applying layers of epoxy and fiberglass to restore its original shape and strength. I also began repairing the teak shoe, meticulously filling the woodworm holes with epoxy resin and then topping it off with an epoxy filler.
It’s a slow process, but it’s incredibly satisfying to see everything come together. Every layer of epoxy, every piece of fibreglass, is another step closer to getting our boat back in the water. This was a major hurdle, and overcoming it has given us the motivation we need to tackle the rest of the refit.
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