Rudder Mold – Take 3?
by Jake on Aug.19, 2007, under Miscellaneous
Ok, hopefully for the 3rd and final time, I attempted to make the second half of the rudder mold. If you remember, the first time, the gelcoat pulled away from the plug leaving a very uneven surface. The second time, the mold warped (and cracked after I tried to straighten it) after I heated it to accelerate curing of the first rudder. This time, I think I have it! The first half of the mold was still in good shape although it did show a slight curve from top to bottom. I fixed that by vacuum bagging two 3/4″ threaded rods (secured from the scrap bin at work) to the back of the mold and clamping it straight. I remade the second half of the mold using 3 layers of 3.5oz cloth and two layers of 17oz nytex cloth – regular ‘ol polyester resin. Once that cured and before separating the two halves, I vacuum bagged two more threaded rods to the back of this half too. They weigh like 4 pounds each, but they’re flat as a board and never warping again! I did, however, scratch the thing while cleaning up the trailing edge…I should be able to repair it.
