Firefly (C&C 27 III) has a similar problem. We installed set screws for the 
drain holes which allow the 2-3 cups of water to drip out in the fall. Sealed 
with Vaseline when the set screws go in at spring launch. No issues this way.

Sent from my iPhone

On Jan 5, 2022, at 12:31 PM, Brian Davis via CnC-List <cnc-list@cnc-list.com> 
wrote:


Thank you, Spencer.

Makes sense. I'm in south Florida, so we never get a freeze. I drilled a couple 
more holes, dug around with a screwdriver, vacuumed it a lot, and have had my 
heat gun blowing in the area for about 3 hours now...at a safe distance.  Its 
seems pretty dry, but I'm going to let her set in the sun for several days. 
Fortunately, I don't think its to bad. The upper 75% seems very dry since I 
drilled out one of the foam fill holes when they made it.

Overall I think I roll with this fix and monitor it next time I haulout.

Really appreciate having this group to turn to for advice and stories.

Regards,
Brian

On Wed, Jan 5, 2022, 12:04 PM Spencer Johnson via CnC-List 
<cnc-list@cnc-list.com<mailto:cnc-list@cnc-list.com>> wrote:
Hi Brian...I replaced my rudder in 2018 after years of bringing it home over 
the winter to let it drain out of the rudder-shaft connection.  I gave up and 
had Competition Composites (cci.one) in Ontario repair it.   Their computer 
scanned the rudder, removed the fiberglass and foam confirming that the SS post 
was in good shape (because of the black/brown tarry ooze that came out of the 
rudder I was relieved), then they scanned the shaft.  After cleaning it all up 
they used a CNC milling machine to cut two halves of hard Divinycell foam - 
inside and outside - then packed with epoxy.  The outside was covered in 2 
layers of fiberglass mat, vacuum bagged, then faired and primed.  Some pics:

https://drive.google.com/drive/folders/0Bz49si3Z0GdDd2sxVXNHV1Iwc0E?resourcekey=0-mxt2XK3szmOGKjPR91NARA&usp=sharing<https://na01.safelinks.protection.outlook.com/?url=https%3A%2F%2Fdrive.google.com%2Fdrive%2Ffolders%2F0Bz49si3Z0GdDd2sxVXNHV1Iwc0E%3Fresourcekey%3D0-mxt2XK3szmOGKjPR91NARA%26usp%3Dsharing&data=04%7C01%7C%7Cdc1a51cde9014505e83c08d9d07125f4%7C84df9e7fe9f640afb435aaaaaaaaaaaa%7C1%7C0%7C637770006649032316%7CUnknown%7CTWFpbGZsb3d8eyJWIjoiMC4wLjAwMDAiLCJQIjoiV2luMzIiLCJBTiI6Ik1haWwiLCJXVCI6Mn0%3D%7C3000&sdata=tWxxqTees3bfSInxG7TCXsiOgiEfMUwKog%2BV55robOM%3D&reserved=0>

They have a video of the process on the website.  Cost was about 3k but the 
exchange rate US to CDN was quite favorable.  Shipping was not cheep...a crate 
cost about $100 and was very well made.  Rudder weight dropped in half....from 
325 to 150 lbs...much easier to reinstall!

Brian....if your boat is outside in the frozen tundra you can be sure it won't 
just get better.  I had the yard use G-Flex on the shaft to rudder 
joint...water still got in.  So, not a matter of IF but WHEN.  For me...I was 
done removing the rudder each fall and taking it home so it would not freeze.  
The new rudder is solid peace of mind.  Good Luck!!

Spencer Johnson
84 LF38 "Alegria"  #165
Racine, WI / Waukegan, IL



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