New rudder just fitted and in process of setting the gudgeon & pintle bearing pairs with filler before rounding over the bolt ends and glassing over.
This rudder is foam sandwich construction.  2 layers of foam to form the shape and layerd up with CSM and woven double bias.  I have incorporated an internal skeleton of stainless steel that is connected to the rudder post and both bearing sets.  Apart from the strength, it will also electrically connect all the metal surfaces associated with the rudder back to earth.  The actual fiberglassing and shaping work was done by a mate of mine who was later banished to China where he is being kept as a slave building 80' luxury ocean going cruisers for rich Chinese boaties.  He occasionally escapes to Hong Kong from where he calls me occasionally from some luxury hotel lobby bar as he gains some much needed R&R.  On ya Gramac.

Note that we have deviated from the original design slightly in that the trailing edge (bottom corner) of the rudder is no longer a curve.  In researching rudder design, I read that a right angled trailing corner performs better.  Trying to make her steer a bit in reverse.  Drawback is when you reverse in to shallow water, that trailing edge becomes the first thing that will hit.  If it proves to be an issue, it can easily be cut back to the original shape and re glassed.  That's the beauty of the product.

Shows the stainless skeleton.