Sailing NV · video

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After striking a reef, the crew of NV lost a 35-centimeter sacrificial section of their 3.5-meter rudder.1:42 To prevent delamination of the PVC closed-cell foam core caused by vibration and water ingress, they fabricated a custom carbon fiber "shoe" to cap the damaged area.0:32 The repair process involved testing underwater bonding agents, including Bostik silicone and low-density epoxy filler, to determine which material provided the best mechanical bond to the foam and fiberglass.4:09 After confirming the epoxy’s superior rigidity, Timo created a mold of the rudder’s profile using PVC and tape, then laminated the carbon fiber shoe using Axial 45/45 and twill weave.12:03 The crew used battery-operated dive gear to clean the damaged rudder, cut a V-shape to remove loose material, and finally bonded the carbon shoe to the rudder using epoxy and mechanical screws.10:37 This temporary underwater repair allowed the boat to continue sailing until they reached a boatyard in northern Borneo for a permanent haul-out repair.17:24

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