littlewing wrote:
I was surprised how out of fair my rudders were. If you make a rigid, semi-flexible sanding block, and run it over the rudders you see how out of fair they are. I'm not sure a belt sander will adequately fair out the shape. A bright light angled properly will also let you see where the concaves are. Not sure if you tried this, or not.
After I got it sanded a bit, I still had some concaves towards the trailing edge of the rudder, and didn't want to take any more off the trailing edge, as the rudders would become more flexible. So, I built up and filled in the areas with West System epoxy with a little bit of fairing compound, and graphite powder. After getting the rudders shaped right, they did several layers of epoxy and graphite, they barely hum at all now, at high speed.
I think part of the problem with the older rudders is the surface becomes less smooth as the plastic oxidizes (or atleast that's what is seemed like on mine), and gives the rudders a high surface roughness. The flow of water over a rougher surface is more like to create small turbulence that could propagate and lead to some real noisy rudders. This is just another idea, if you are sure the rudders are faired properly. The epoxy and graphite give the rudders a very low surface tension, and help let the water break off more easily.
just another thought on it.
A high quality wax would also help if the surface roughness is part to blame.