what to drill and fill rudder?

I have a rudder where the lower hole is pretty far off (from the Hobie template). So much so that, in the parked (up) position, the rudder points upwards around 30 degrees. I'm going to fill and drill it. I was wondering what is the recommended fill? I have some Marine Tex on hand and also some long strand epoxy marine filler. Are either of these appropriate? Not sure what the rudder is made of. The only marking is "XX1" or "XXI" and below that is "AH". The rudder is white and appears to be a solid material (no lamination's).

I'd use colloidal silica powder and epoxy resin (because I have a supply from boat building hobby) but hope I don't start another distasteful epoxy / polyester slugfest here.

I guess the question is what sticks best to plastic? The rudder is either Lexan or ABS - both plastics. I think a friend of mine may have some vinylester too. Hopefully someone here has done this before and can tell me what works and what does not. The new and existing holes may overlap a bit.

Yep. Tickened epoxy.

Distasteful, Chris? How about educational?

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Okay thanks. I have some West systems epoxy and my buddy has some silica powder. I thought I would take a keyhole hacksaw and cut some slots or ridges in the existing holes so it would be less of a cylindrical plug.

Not a bad idea! Put some tooth on that sucker.

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Ah, epoxy

There was a good article on this in the Vol. 2 Issue 7 of the May/June 1998 OnTheWire by Bill Mattson on "Raking Rudders".

http://www.thebeachcats.com/OnTheWire/wwwcatsail/archives/v2-i7/feature3.htm

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Tim
84 H16
82 H16
87 H14T
Tortola Sails: 115222
Blue Prism Sails: 88863
Clearwater, FL

He used Marine Tex. I had some on hand so I went ahead and used it too. The box says "cures hard as steel" blah blah blah. I've had good luck with Marine Tex on other stuff.

Matt Mattson used JB Weld for his final adjustment and I also used it a couple of years ago since I also had to move the holes and re-drill them more than once to get the right rake on my lexan rudders. The JB Weld has maintained a round hole even though the last set of holes I drilled were partly thru the JB Weld. Shifting the holes just a half of a hole diameter can make all the difference in your weather helm.

_________________
Tim
84 H16
82 H16
87 H14T
Tortola Sails: 115222
Blue Prism Sails: 88863
Clearwater, FL