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Zeal shapes a new rudder for the Tally Ho using Purpleheart, a dense tropical hardwood.2:07 He uses an adze and power tools to profile the leading edge and feather the prop aperture for hydrodynamic efficiency.1:52 To ensure alignment of the gudgeons and pintles, the team uses a string line threaded through aluminum discs.6:12 During the first attempt to hang the rudder, the pintles fail to seat fully into the gudgeons due to tight tolerances.8:12 After fine-tuning the pintle positions and lapping the metal surfaces to increase clearance, the team successfully hoists and seats the rudder on the stern.8:28 Additional work includes fitting cap rail sections, including a wider section for the pin rail, and preparing the hull for final paint by filling seams with topside compound.16:58

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