Refit workshopNew rudder blade for an old classic

Lasse Johannsen

 · 23.08.2023

The new rudder blade is glued from three layers of 15 mm sapele peeled veneer marine plywood. These are cut to oversize using a hand-held circular saw
Photo: YACHT/S. Hucho
The rudder blade refit step by step in detail
The replacement for a desolate rudder blade had to be as robust and economical as possible - and in keeping with the style. This is how the refit of a 60-year-old classic succeeded

Not much is known about the motor cutter, which was built in 1962 at the Lübeck boatyard Fritz Staack & Co and is now at the Alveus Bootsbau shipyard in Potsdam, where its owner is having it completely restored. The freshly refurbished shipyard plaque identifies the cutter as construction number 1.283, and since it also has a supply number on it, it is at least clear that it must be a vessel originally built for the navy. Presumably a transfer boat or a cutter used for training purposes.

The open ship has had a built-in engine since it was launched, but can also be sailed and rowed. The rig has two masts and is gaff-rigged. Due to the different types of use, the rudder blade is fitted with an insert that extends it aft. However, this does not alter the fact that the design can be used as a model for any other rudder blade.

Classic refit: New rudder blade construction requires the use of very different tools

The new rudder blade was made from plywood with inexpensive peeled veneer. The owner's original intention was to have it painted white, which is why the appearance of the wooden surface was of secondary importance. In the end, however, the result was so convincing that the rudder blade was given a natural varnish finish.

The jaws, between which the tiller is guided, are made of high-quality plywood, the surface of which forms a sliced thick veneer. Epoxy resin was used for the gluing, which was also used to coat the entire rudder blade after completion.

The original rudder blade of the motor cutter from the year of construction served as a model, but it was in such a desolate condition that it could not be restored and therefore had to be completely rebuilt. The work was carried out at Alveus boatbuilding a young classic shipyard from Potsdam.


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