Jon
Type the word rudder in the search box above and you will find volumns of information on what others have done. Here is a link to just one small portion of what you will find.
http://www.pearsonariel.org/discussi...ghlight=RUDDER
Also here is a link to a company that can build you a nice new fiberglass version (at a pretty steep price). If you decide to go with Foss Foam to have them build you a new rudder, they will need to make a new mold which is the expensive part and the reason I have not choosen to go with them. However we might be able to cut a deal that is better if they were to build two rudders one for me and one for you.
http://newrudders.com/?page_id=6
Currently my plan is to buy the marine bronze and have a local machine shop do the fabricating to it and build a new rudder body out of some 6/4 quartersawn mahogany I already have and then "possibly" cover it in fiberglass. The jury is still out on the last part.
Your milage may vary :-)
JERRY CARPENTER - C147
A man can succeed at almost anything for which he has unlimited enthusiam.