I have been reworking the rudders on my '85 HC16 and have some questions (
in red throughout).
I removed everything from the transoms except the drains. I was able to remove all gudgeon screws without breaking any.
I installed new one-piece die cast gudgeons. I had to englarge the mounting holes in the gudgeons because of the known alignment problems. I used the new style locking gudgeon screws. I also had to grind a little off the lower rudder castings since the gudgeon mounting screws interfere with rudder swing.
First questions: Is it necessary to install screws in the two bottom holes of the gudgeons? And if so, then I assume holes need to be drilled and tapped in the hull/aluminum backing plate(none exist there now)?
I replaced the aluminum rudder pins with new stainless steel ones. I still have a little play between the rudder castings and the pins so will likely also install rudder casting bushings. It sure would have been nice if Hobie had made the bearings easily replacable.
Question: Without taking them to a machine shop, how do you accurately drill out the rudder casting so you can insert the new bushings? I'm a little concerned about alignment
I drilled out the cam rivets and will install the new cams with sister screws. I drilled out the brittle old rudder locking screws using the method mentioned on this forum- I used a woodworking spade bit to remove most of the plastic then cleaned the threads with a 3/4" bolt. I made length-wise relief cuts in a 3/4" X 6" machine bolt to make it like a tap and used that to clean the threads. It worked well. I lubricated and installed new plungers, springs, and delrin screws- what a difference!
I also had to drill out the screws and clean the threads of the 3/8" rudder rake adjusting screws. Until I get the delrin replacements I am using some SS set screws.
Questions: Any problem with just using a stainless steel adjusting screw? Do you think it will damage the rudders?
Except as noted, this work is going well and should hopefully result in much smoother and tighter rudder operation.