Rudder Build - Offset Rail Method - Sharpie Build - V64 Rudder Pt1

Heavy rain outside meant a pause on the trailer build — so I headed into the shed to start on something new: the rudder blade for my 23ft (7m) Sharpie trailer yacht. In this video, I use the offset rail routing method to machine a NACA 0012 foil into the rudder. I’d never tried this technique before, and it looked a bit intimidating at first — but step by step, it turned out to be straightforward and accurate. After some minor refinements and a full day of routing, I ended up with a clean, fair blade that only needed a light sand and fill before glassing. Then came the fiberglassing — four layers of 400gsm cloth near the top, all done in one session. It was ambitious (and late in the day), and I ran into a few air pockets I just couldn’t remove. Frustrating, but a great learning experience for next time! If you’re interested in DIY yacht building, precision routing, or composite techniques, you’ll enjoy seeing how this process comes together.