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James builds a replacement rudder from scratch for Triteia, his 1965 Alberg 30, while hauled out in Thailand during a mid-circumnavigation refit.0:16 The original all-wood rudder broke free from the tiller post in August 2021 after striking a partially submerged shipping container while sailing between Los Angeles and Hawaii, forcing him to steer 1,000 miles to Hawaii using a drogue.0:59 Bronze tangs were welded to the tiller shaft in Hawaii as a temporary fix; the decision to build a full replacement came during a haul-out in Langkawi, Malaysia.1:17

The build uses thickened epoxy with fast-setting hardener for sculptural shaping and gap-filling, six-ounce fiberglass cloth taped over all edges, and a final solid glass sheet over the whole blade.1:45 Barrier coat additive goes into all final epoxy layers to block moisture.4:26 Packaging tape serves as a release agent when bedding the tiller post interface in place on the boat, producing a precise fit.2:28 Nylon spacers control vertical play at the shoe mount; Sikaflex with nylon lock nuts and lock washers beds the bronze hardware.22:21 The complete project took six and a half weeks.26:41 Stainless steel fittings were supplied by Raleigh Tasker in Thailand, described as a one-stop shop for sails, rigging, spars, and stainless fabrication.26:58 The next project is a Beta Marine engine installation.0:23

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