The rudder looked like a broken leg, flopped over to the side. “Oh no…” I thought. The last time I saw this we were in El Salvador and a bolt had come underdone. This time it was a lot more serious, and we were a lot more remote… 50 miles from the closest village in Tahanea, an uninhabited atoll in Tuamotos.
Like El Salvador, we had just endured two rough nights at anchor. On the heels of a low pressure, 20-25kt South winds blew across Tahanea’s lagoon and caused 2 foot waves to crash onto our bow at anchor. Due to poor visibility from the rainstorm, we chose not to traverse the lagoon to find smooth water on the other side. The lagoon is uncharted, and coral bommies can pop up from 50 foot depths to 3-5 feet deep. One of our sailor friends had hit a coral bommie when visibility had been reduced and was stuck on the rocks for 12hours, sustaining significant damage to the keel.
“Only traverse the lagoon when visibility is good,” was the word of warning. So we chose to stay in the exposed Middle Anchorage. Comfort-wise, we were fine on Aldebaran, but as the waves shuddered the boat backwards at anchor. Normally there is a rudder lock which keeps the rudder straight. However, the rudder lock failed and the waves overloaded the rudder. This put an enormous amount of stress on the rudder arm, which is a stout but old cast bronze piece, and it cracked in half.
The failure of the rudder arm is catastrophic to the boat’s operation- it means we can’t steer the boat. The piece takes huge amounts of stress, and holds the stainless steel rudder shaft with a very specific “key-way”, so to fix it was a serious project. To avoid falling into desperation, we had to start a new company: Bad Ass Engineering. Company policy requires that we drink rum at regular intervals, speak with a southern accent, and git ‘er dune no matter what.
The Bad Ass team (aka B & A) crawled into Aldebaran’s wood locker and found some pieces of mahogany. We chopped them up and drilled lots of holes to connect them to the bronze rudder arm. This process took all day.
The mahogany wood allowed us to “marry” the two pieces of bronze, using 11 bolts and 3 pieces of wood. We also added epoxy to bind the pieces and fill in the gaps.
The end result: ROBO RUDDER.