The rudder had a major crack running from the bottom, three fourths of the way up and some small cracks, also starting at the bottom.  The major crack was wedged open and epoxy applied full length of the crack.  The rudder was then clamped together.

All low areas were filled with epoxy/filler (grey) and sanded smooth. The smaller cracks were filled with un-thickened epoxy and allowed to "wick" into the wood.  Two barrier coats of epoxy (below waterline) were applied prior to the final colored gel coat application.

 

Original rudder, split up center

Wicking epoxy into small cracks

origional

small cracks in rudder
   
Barrier coating with epoxy prior to gel coat application Barrier coat #1 finished

ready to wet sand and recoat

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