I made a mold from the old rudder but made it a bit wider to accomodate double head sail combination. I layed a piece of plastic to the bottom and sides of the mold so the epoxy wouldn't stick to the wood.

I then laid some glass cloth top and bottom to give some added strength.

I mixed up a big batch of epoxy with 407 and 410 filler and poured it in the mold over the stainless post and pins.

Then I mixed another batch to top it off.

After the epoxy set up I stripped from the form, it was an inch and a half thick all the way around.

I took the blank out back to the grinding table and started grinding away to give it the shape I desired.

Notice the derelict in the background as I grind away...

... until I got the shape I wanted.

Then I glassed both side for further added toughness.

The next step will be to prime and paint it when I finsh the hull.