Pipe Rudder Part IV

[Bob Smalser]

Previous:


http://www.sawmillcreek.org/showthread.php?t=15032&highlight=pipe+rudder

http://www.sawmillcreek.org/showthread.php?t=15910&highlight=pipe+rudder

http://www.sawmillcreek.org/showthread.php?t=15945

http://www.sawmillcreek.org/showthread.php?t=16263

Rudder housing is located on installed shaft. Batten marks where ground will be on the beached boat:

http://pic3.picturetrail.com/VOL12/1104763/6035832/83320019.jpg

A flat is milled on the rudder shaft for the housing using a carbide-tipped router bit prior to cutting shaft to length…the installed yoke was left squared for easy alignment of the flat:

http://pic3.picturetrail.com/VOL12/1104763/6035832/83320007.jpg

Housing base is attached temporarily with machine screws to fix for brazing…

http://pic3.picturetrail.com/VOL12/1104763/6035832/83320002.jpg

…and after brazing is cleaned up and checked for true prior to brazing housing cheeks:

http://pic3.picturetrail.com/VOL12/1104763/6035832/83319994.jpg

Assembly is aligned and fluxed for final brazing operation:

http://pic3.picturetrail.com/VOL12/1104763/6035832/83319975.jpg

High-strength silver braze is flowed into the joints by capillary action at 1300 degrees:

http://pic3.picturetrail.com/VOL12/1104763/6035832/83320389.jpg

http://pic3.picturetrail.com/VOL12/1104763/6035832/83320383.jpg

Continued…

[Bob Smalser]

Joints and imperfections are faired using soft solder at 450 degrees…

http://pic3.picturetrail.com/VOL12/1104763/6035832/83320501.jpg

http://pic3.picturetrail.com/VOL12/1104763/6035832/83320370.jpg

…and then cross and draw filed fair:

http://pic3.picturetrail.com/VOL12/1104763/6035832/83320361.jpg

http://pic3.picturetrail.com/VOL12/1104763/6035832/83320378.jpg

After finishing with abrasive paper, the unfinished rudder blade is tested for fit through the full range of positions before boring and fabricating pin and adding final layer of 3oz cloth and 6 coats of spar:

http://pic3.picturetrail.com/VOL12/1104763/6035832/83400489.jpg

http://pic3.picturetrail.com/VOL12/1104763/6035832/83400528.jpg

To be continued…