The Emergency Rudder Cassette Close-up
Any outboard rudder system which uses pintles and gudgeons is inherently weak.  Be sure your design tries to address the loads which will be placed on  the system.
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This is the area which failed on version 1.  The original gudgeons were fastened directly onto the white plywood piece at the front of the cassette, without the stainless tangs.  They broke immediately.
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The improvements in version 2 are
  • the addition of the triangular piece of wood on the front of the cassette
  • wrapping the top and bottom of the cassette in fiberglass (see previous picture)
  • the bent stainless tangs which wrap around the outside and bolted onto the cassette
  • welding  the gudgeons onto the tangs.

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