New Rudder

I bought a new rudder from Foss Foam and now I have to drill a hole in the shaft in order to attach the tiller. Does anyone have a fool proof method to drill the hole so that everything aligns properly? John B Cal227 #650

John, When I replaced Magic's (Cal 2-27) rudder, we took the old and new one to a machine shop. They have the drill guides to drill through SS pipe. It will be difficult to do on your own without a drill press, etc. You will like the new Foss rudder!!! Michaels/v Imagine, Kaufman 47 From: "'John Boyce' je… [at] gmail.com [Cal_Boats]" <Ca… [at] yahoogroups.com> To: Ca… [at] yahoogroups.com Sent: Monday, April 17, 2017 11:53 AM Subject: [Cal_Boats] New Rudder I bought a new rudder from Foss Foam and now I have to drill a hole in the shaft in order to attach the tiller. Does anyone have a fool proof method to drill the hole so that everything aligns properly? John BCal227 #650 -- {border:1px solid #d8d8d8;font-family:Arial;margin:10px 0;padding:0 10px;} hr {border:1px solid #d8d8d8;} {color:#628c2a;font-size:85%;font-weight:700;line-height:122%;margin:10px 0;} {margin-bottom:10px;} .yiv0088604564ad {padding:0 0;} .yiv0088604564ad p {margin:0;} .yiv0088604564ad a {color:#0000ff;text-decoration:none;} {font-family:Arial;} {margin:10px 0px;font-weight:700;font-size:78%;line-height:122%;} .yiv0088604564ad {margin-bottom:10px;padding:0 0;} {font-family:Verdana;font-size:11px;padding:10px 0;} {background-color:#e0ecee;float:left;font-family:Verdana;font-size:10px;padding:10px;} span {font-weight:700;} span:first-child {text-transform:uppercase;} span a {color:#5085b6;text-decoration:none;} span span {color:#ff7900;} span .yiv0088604564underline {text-decoration:underline;} .yiv0088604564attach {clear:both;display:table;font-family:Arial;font-size:12px;padding:10px 0;width:400px;} .yiv0088604564attach div a {text-decoration:none;} .yiv0088604564attach img {border:none;padding-right:5px;} .yiv0088604564attach label {display:block;margin-bottom:5px;} .yiv0088604564attach label a {text-decoration:none;} blockquote {margin:0 0 0 4px;} .yiv0088604564bold {font-family:Arial;font-size:13px;font-weight:700;} .yiv0088604564bold a {text-decoration:none;} dd.yiv0088604564last p a {font-family:Verdana;font-weight:700;} dd.yiv0088604564last p span {margin-right:10px;font-family:Verdana;font-weight:700;} dd.yiv0088604564last p span.yiv0088604564yshortcuts {margin-right:0;} div.yiv0088604564attach-table div div a {text-decoration:none;} div.yiv0088604564attach-table {width:400px;} div.yiv0088604564file-title a, div.yiv0088604564file-title a:active, div.yiv0088604564file-title a:hover, div.yiv0088604564file-title a:visited {text-decoration:none;} div.yiv0088604564photo-title a, div.yiv0088604564photo-title a:active, div.yiv0088604564photo-title a:hover, div.yiv0088604564photo-title a:visited {text-decoration:none;} div p a span.yiv0088604564yshortcuts {font-family:Verdana;font-size:10px;font-weight:normal;} .yiv0088604564green {color:#628c2a;} .yiv0088604564MsoNormal {margin:0 0 0 0;} o {font-size:0;} div {float:left;width:72px;} div div {border:1px solid #666666;height:62px;overflow:hidden;width:62px;} div label {color:#666666;font-size:10px;overflow:hidden;text-align:center;white-space:nowrap;width:64px;} {font-size:77%;} {font-size:77%;} .yiv0088604564replbq {margin:4px;} div a:first-child {margin-right:2px;padding-right:5px;} {font-size:13px;font-family:Arial, helvetica, clean, sans-serif;} table {font-size:inherit;font:100%;} select, input, textarea {font:99% Arial, Helvetica, clean, sans-serif;} pre, code {font:115% monospace;} * {line-height:1.22em;} {padding-bottom:10px;} p a {font-family:Verdana;} p span {color:#1E66AE;font-weight:700;} {color:#ff7900;font-weight:700;} {margin-bottom:20px;padding:0px;} li a {font-size:130%;text-decoration:none;} li {font-size:77%;list-style-type:square;padding:6px 0;} ul {margin:0;padding:0 0 0 8px;} {font-family:Georgia;} p {margin:0 0 1em 0;} tt {font-size:120%;} ul li:last-child {border-right:none !important;}

John, can't help you but am interested to know why you replaced yours. I have a crack in the rudder that came with my boat and I'm preparing for the worst. You being proactive or did you have a failure? On Mon, Apr 17, 2017 at 9:53 AM, 'John Boyce' je… [at] gmail.com [Cal_Boats] < Ca… [at] yahoogroups.com> wrote: > > > I bought a new rudder from Foss Foam and now I have to drill a hole in the > shaft in order to attach the tiller. Does anyone have a fool proof method > to drill the hole so that everything aligns properly? > > > > John B > > Cal227 #650 > > > -- *Donald J Thomas* Broker Associate *LIV Sotheby's International Realty* 101 S. Main St. Breckenridge, Colorado 970-409-9133 www.teamthomasmountainhomes.com

Cutting stainless steel is tricky but not impossible. SS work-hardens (which means it gets harder as you cut it) so once you start your drilling, do not stop until you are thru. Go slow and use lots of lubricant/coolant. Using a drill press is much preferred. You could use the existing tiller fitting as a drill guide, drilling in from each side of the fitting so that the holes line up properly. Jeff Thayer S/V Ecco Cal 39 Mk2

On my Cal 29, and I assume on most tiller steering, there is a fitting that slips on to the rudder post and gets a bolt that goes in one side and out the other to keep it on the post. The tiller then gets attached to this fitting. Assuming the rudder post on the new rudder is the same as the one on the old rudder, measure down from the end of the old rudder post to where the holes are. Transfer this measurement to the new rudder post and mark it. Take the afore mentioned fitting and place it on the new rudder post where you marked it. Secure the fitting at this point. Take a sharp drill bit the same size as the bolt and drill the holes in the rudder shaft. Don't try to drill all the way through from one side to the other. Drill one side and then drill from the other side. After drilling both holes you can now go from one side all the way through to the other side to make sure they line up. Leave the fitting in place for this last step. Now you should be ready to finish. The rudder shaft is not hard to drill through. On Monday, April 17, 2017 11:53 AM, "'John Boyce' je… [at] gmail.com [Cal_Boats]" <Ca… [at] yahoogroups.com> wrote: I bought a new rudder from Foss Foam and now I have to drill a hole in the shaft in order to attach the tiller. Does anyone have a fool proof method to drill the hole so that everything aligns properly? John BCal227 #650 -- {border:1px solid #d8d8d8;font-family:Arial;margin:10px 0;padding:0 10px;} hr {border:1px solid #d8d8d8;} {color:#628c2a;font-size:85%;font-weight:700;line-height:122%;margin:10px 0;} {margin-bottom:10px;} .yiv8217930932ad {padding:0 0;} .yiv8217930932ad p {margin:0;} .yiv8217930932ad a {color:#0000ff;text-decoration:none;} {font-family:Arial;} {margin:10px 0px;font-weight:700;font-size:78%;line-height:122%;} .yiv8217930932ad {margin-bottom:10px;padding:0 0;} {font-family:Verdana;font-size:11px;padding:10px 0;} {background-color:#e0ecee;float:left;font-family:Verdana;font-size:10px;padding:10px;} span {font-weight:700;} span:first-child {text-transform:uppercase;} span a {color:#5085b6;text-decoration:none;} span span {color:#ff7900;} span .yiv8217930932underline {text-decoration:underline;} .yiv8217930932attach {clear:both;display:table;font-family:Arial;font-size:12px;padding:10px 0;width:400px;} .yiv8217930932attach div a {text-decoration:none;} .yiv8217930932attach img {border:none;padding-right:5px;} .yiv8217930932attach label {display:block;margin-bottom:5px;} .yiv8217930932attach label a {text-decoration:none;} blockquote {margin:0 0 0 4px;} .yiv8217930932bold {font-family:Arial;font-size:13px;font-weight:700;} .yiv8217930932bold a {text-decoration:none;} dd.yiv8217930932last p a {font-family:Verdana;font-weight:700;} dd.yiv8217930932last p span {margin-right:10px;font-family:Verdana;font-weight:700;} dd.yiv8217930932last p span.yiv8217930932yshortcuts {margin-right:0;} div.yiv8217930932attach-table div div a {text-decoration:none;} div.yiv8217930932attach-table {width:400px;} div.yiv8217930932file-title a, div.yiv8217930932file-title a:active, div.yiv8217930932file-title a:hover, div.yiv8217930932file-title a:visited {text-decoration:none;} div.yiv8217930932photo-title a, div.yiv8217930932photo-title a:active, div.yiv8217930932photo-title a:hover, div.yiv8217930932photo-title a:visited {text-decoration:none;} div p a span.yiv8217930932yshortcuts {font-family:Verdana;font-size:10px;font-weight:normal;} .yiv8217930932green {color:#628c2a;} .yiv8217930932MsoNormal {margin:0 0 0 0;} o {font-size:0;} div {float:left;width:72px;} div div {border:1px solid #666666;height:62px;overflow:hidden;width:62px;} div label {color:#666666;font-size:10px;overflow:hidden;text-align:center;white-space:nowrap;width:64px;} {font-size:77%;} {font-size:77%;} .yiv8217930932replbq {margin:4px;} div a:first-child {margin-right:2px;padding-right:5px;} {font-size:13px;font-family:Arial, helvetica, clean, sans-serif;} table {font-size:inherit;font:100%;} select, input, textarea {font:99% Arial, Helvetica, clean, sans-serif;} pre, code {font:115% monospace;} * {line-height:1.22em;} {padding-bottom:10px;} p a {font-family:Verdana;} p span {color:#1E66AE;font-weight:700;} {color:#ff7900;font-weight:700;} {margin-bottom:20px;padding:0px;} li a {font-size:130%;text-decoration:none;} li {font-size:77%;list-style-type:square;padding:6px 0;} ul {margin:0;padding:0 0 0 8px;} {font-family:Georgia;} p {margin:0 0 1em 0;} tt {font-size:120%;} ul li:last-child {border-right:none !important;}

We really ruddered. CAL 36 NOTICE that if you lay rudder Down on one side hole appeared To be 90° at that point ...we drilled small hole through both walls of Stainless steel shaft. Then Enlarged each by drilling in.. Take your time it nice to Have everything a tight fit.. Edward On Apr 17, 2017 8:53 AM, "'John Boyce' je… [at] gmail.com [Cal_Boats]" < Ca… [at] yahoogroups.com> wrote: > > > I bought a new rudder from Foss Foam and now I have to drill a hole in the > shaft in order to attach the tiller. Does anyone have a fool proof method > to drill the hole so that everything aligns properly? > > > > John B > > Cal227 #650 > >

Regarding old rudders, I have an issue of "Ocean Navigator" from 1997, the year I bought "Shpritz" and it's called "Rudderless off Cape Horn". The sailor had sleeved her Cal 39 rudder shaft, but that's not what broke. What broke is the metal ribs that run from the shaft into the rudder fin. There's a seroes on Youtube featuring the total rebuild of a Cal 40 and they reported the same thing when they looked at the old rudder which they had already planned to replace with a new Foss model.I guess if you kept the rudder out of rough seas it might still be strong enough, but breaking in rough seas which can be unpredictable is the last situation where you'd want to be rudder-challenged.Jerry of Yea Olde Shpritz. On Monday, April 17, 2017 9:00 AM, "Donald Thomas dn… [at] gmail.com [Cal_Boats]" <Ca… [at] yahoogroups.com> wrote: John, can't help you but am interested to know why you replaced yours. I have a crack in the rudder that came with my boat and I'm preparing for the worst. You being proactive or did you have a failure? On Mon, Apr 17, 2017 at 9:53 AM, 'John Boyce' je… [at] gmail.com [Cal_Boats] <Ca… [at] yahoogroups.com> wrote: I bought a new rudder from Foss Foam and now I have to drill a hole in the shaft in order to attach the tiller. Does anyone have a fool proof method to drill the hole so that everything aligns properly? John BCal227 #650 -- Donald J ThomasBroker AssociateLIV Sotheby's International Realty101 S. Main St.Breckenridge, Colorado 970-409-9133www.teamthomasmountainhomes.com -- {border:1px solid #d8d8d8;font-family:Arial;margin:10px 0;padding:0 10px;} hr {border:1px solid #d8d8d8;} {color:#628c2a;font-size:85%;font-weight:700;line-height:122%;margin:10px 0;} {margin-bottom:10px;} .yiv6676365399ad {padding:0 0;} .yiv6676365399ad p {margin:0;} .yiv6676365399ad a {color:#0000ff;text-decoration:none;} {font-family:Arial;} {margin:10px 0px;font-weight:700;font-size:78%;line-height:122%;} .yiv6676365399ad {margin-bottom:10px;padding:0 0;} {font-family:Verdana;font-size:11px;padding:10px 0;} {background-color:#e0ecee;float:left;font-family:Verdana;font-size:10px;padding:10px;} span {font-weight:700;} span:first-child {text-transform:uppercase;} span a {color:#5085b6;text-decoration:none;} span span {color:#ff7900;} span .yiv6676365399underline {text-decoration:underline;} .yiv6676365399attach {clear:both;display:table;font-family:Arial;font-size:12px;padding:10px 0;width:400px;} .yiv6676365399attach div a {text-decoration:none;} .yiv6676365399attach img {border:none;padding-right:5px;} .yiv6676365399attach label {display:block;margin-bottom:5px;} .yiv6676365399attach label a {text-decoration:none;} blockquote {margin:0 0 0 4px;} .yiv6676365399bold {font-family:Arial;font-size:13px;font-weight:700;} .yiv6676365399bold a {text-decoration:none;} dd.yiv6676365399last p a {font-family:Verdana;font-weight:700;} dd.yiv6676365399last p span {margin-right:10px;font-family:Verdana;font-weight:700;} dd.yiv6676365399last p span.yiv6676365399yshortcuts {margin-right:0;} div.yiv6676365399attach-table div div a {text-decoration:none;} div.yiv6676365399attach-table {width:400px;} div.yiv6676365399file-title a, div.yiv6676365399file-title a:active, div.yiv6676365399file-title a:hover, div.yiv6676365399file-title a:visited {text-decoration:none;} div.yiv6676365399photo-title a, div.yiv6676365399photo-title a:active, div.yiv6676365399photo-title a:hover, div.yiv6676365399photo-title a:visited {text-decoration:none;} div p a span.yiv6676365399yshortcuts {font-family:Verdana;font-size:10px;font-weight:normal;} .yiv6676365399green {color:#628c2a;} .yiv6676365399MsoNormal {margin:0 0 0 0;} o {font-size:0;} div {float:left;width:72px;} div div {border:1px solid #666666;height:62px;overflow:hidden;width:62px;} div label {color:#666666;font-size:10px;overflow:hidden;text-align:center;white-space:nowrap;width:64px;} {font-size:77%;} {font-size:77%;} .yiv6676365399replbq {margin:4px;} div a:first-child {margin-right:2px;padding-right:5px;} {font-size:13px;font-family:Arial, helvetica, clean, sans-serif;} table {font-size:inherit;font:100%;} select, input, textarea {font:99% Arial, Helvetica, clean, sans-serif;} pre, code {font:115% monospace;} * {line-height:1.22em;} {padding-bottom:10px;} p a {font-family:Verdana;} p span {color:#1E66AE;font-weight:700;} {color:#ff7900;font-weight:700;} {margin-bottom:20px;padding:0px;} li a {font-size:130%;text-decoration:none;} li {font-size:77%;list-style-type:square;padding:6px 0;} ul {margin:0;padding:0 0 0 8px;} {font-family:Georgia;} p {margin:0 0 1em 0;} tt {font-size:120%;} ul li:last-child {border-right:none !important;}

I drilled the rudder shaft today. First I had to deburr and polish the end of the shaft so that I could get the rudder post cap on, measuring the old shaft to make sure that the cap was inserted the same on the new shaft. I then attached the tiller to the rudder post cap and aligned the tiller with the new rudder. I then tightened the rudder post cap onto the rudder shaft and removed the tiller. I then used the existing holes in the rudder post cap as guide as and drilled slowly with oil, and a lot of pressure 25/64" holes on each side. Finally I deburred and polished around the new holes. Now if the shaft fits in the fiberglass tube I'll be able to launch the boat Monday. Thanks to all for your suggestions. John B Cal 227. #650 Gotcha Again On Apr 20, 2017 9:08 PM, "Gerald Sobel so… [at] yahoo.com [Cal_Boats]" < Ca… [at] yahoogroups.com> wrote: > > > Regarding old rudders, I have an issue of "Ocean Navigator" from 1997, the > year I bought "Shpritz" and it's called "Rudderless off Cape Horn". The > sailor had sleeved her Cal 39 rudder shaft, but that's not what broke. What > broke is the metal ribs that run from the shaft into the rudder fin. > There's a seroes on Youtube featuring the total rebuild of a Cal 40 and > they reported the same thing when they looked at the old rudder which they > had already planned to replace with a new Foss model. > I guess if you kept the rudder out of rough seas it might still be strong > enough, but breaking in rough seas which can be unpredictable is the last > situation where you'd want to be rudder-challenged. > Jerry of Yea Olde Shpritz. > > > On Monday, April 17, 2017 9:00 AM, "Donald Thomas dn… [at] gmail.com > [Cal_Boats]" <Ca… [at] yahoogroups.com> wrote: > > > > John, can't help you but am interested to know why you replaced yours. I > have a crack in the rudder that came with my boat and I'm preparing for the > worst. You being proactive or did you have a failure? > > On Mon, Apr 17, 2017 at 9:53 AM, 'John Boyce' je… [at] gmail.com > [Cal_Boats] <Ca… [at] yahoogroups.com> wrote: > > > I bought a new rudder from Foss Foam and now I have to drill a hole in the > shaft in order to attach the tiller. Does anyone have a fool proof method > to drill the hole so that everything aligns properly? > > John B > Cal227 #650 > > > > > -- > *Donald J Thomas* > Broker Associate > *LIV Sotheby's International Realty* > 101 S. Main St. > Breckenridge, Colorado > 970-409-9133 <(970)%20409-9133> > www.teamthomasmountainhomes.com > > > >