When shipping Tattoo's rudder this afternoon -- I heard water sloshing around inside the rudder. When turned upside down, water very slowly dripped from somewhere near the slot for the tiller. It's a small amount, probably less than a pint of Chesapeake water.
Close inspection shows a hairline crack at the heal of the rudder where it is epoxied to its "wing." I think it happened when [earlier, perhaps 2011 season] the outboard's prop "clipped" the wing. I didn't notice any damage other than a dent into the edge of the wing. I repaired that with some thickened epoxy. I also modified the transom cutout so that the outboard was raised by one inch. At the new height, the wing of the rudder is below the lowest swing of the prop. Also, the skeg (on the lowest point of the outboard's shaft), if pushed against the rudder, hits the wing and prevents the shaft (and the prop) from getting any closer to the rudder. Also, there is a limiting wedge on the tiller that prevents the rudder and outboard shaft from coming too close together (if I remember to move the wedge into place). But now the outboad's skeg actually prevents a collision of the prop and rudder wing (even if the wedge is not in place).
I seem to remember that I coated the inside plywood (of the rudder) with two coats of epoxy before assembly of the rudder. However, I can't remember if I did the same for the structural pieces. My concern is total removal of the water and drying out of any residual moisture. My plan is to drill a 1/4" vent hole thru the rudder near the top of the hollow space. Then place the rudder (broadside) to a heat lamp for several days (maybe even a week or so) keeping the surface temperature relatively high. When I think it's about as dry as it may get, then I'll plug the drilled holes with a 1/4" dowel epoxied in place. Comments, suggestions, please ...
To repair the "hairline" crack I plan to remove the paint around the area by sanding. Then applying first unthickened epoxy and then thickened epoxy. Maybe I should also apply strips of fiberglass over the hairline crack at the same time that I apply the first coat of epoxy. Comments, suggestions, please ...