Hey Scott, I have had a look at the new rudder being built. It looks great. I know there are a number of people here that would enjoy seeing the progress being made and the method that you have chosen. I would encourage you to share any pics that you might have and also pics of the old rudder (both the wood problem and the corrosion of the old shaft) .
I promised a reply, but felt that the reply belonged on the "Rudder Discussion" thread on the technical forum. You will find my reply, a brief technical description of the project and photos there. I did install a new custom redesigned rudder on my boat. While waiting for the rudder to be manufactured, I repaired and resurfaced the nonskid area of the decks and some of he gelcoat areas as well,, so the boat is looking good. The original rudder lasted 53 years in salt water. It was still functioning at the time that I replaced it, but the amount of corrosion in the shaft in the area of the top rudder bolt was substantial. I saved the old rudder and shaft so that I can do some forensic research on the shaft.