Definitely a small soft spot can be repaired without replacing the whole rudder. However the 2" separation indicates some delamination is occurring which is important to address. Especially if the boat lives in the water, this delam will spread until your rudder falls apart.

First, determine if it is the only soft spot and the extent by tapping the entire rudder (hard plastic handle of a screwdriver works well). You'll hear a notably different sound over delaminated areas.

The best repair involves grinding away all the glass over delaminated areas, filling low spots or replacing foam as appropriate, and re-glassing over the repair. Then the gelcoat needs to be repaired as well.

Small delam can sometimes be repaired by drilling holes and injecting epoxy. This might be worth a try if the boat is dry-sailed, but if the boat lives in the water best to fix it right as this fix might still allow water to intrude.

Replacing an E27 rudder is non-trivial and expensive--best to repair the one you have.

::
::
:: :: Since you all are talking about rudder, What would you
:: :: recommend for repair for small (size of pinky) soft spot
:: :: ? I also notice very thin separation of about 2 inch
:: :: length at the trailing edge. Any recommendations for
:: :: repairs are greatly appreciated. I plan to do in late
:: :: fall when E27 is out of water.
::
:: :: Thank you very much.
::
:: :: Yoshi
:: ::
:: ::
:: ::
:: ::
:: :: :: How about me building you a new rudder? You do want a
:: :: :: Class Legal rudder don't you?? I will have to tooling by
:: :: :: September 1st.
:: ::
:: :: :: Ron Moore
:: :: ::
:: :: :: :: I could draw up an outline of the templates that were
:: :: :: :: cut from the drawing Deeds gave me. However, that puts
:: :: :: :: two more generations of possible errors in them,
:: :: :: :: although they worked very well for me. Lemme know.
:: :: :: ::
:: :: :: :: ::
:: :: :: :: :: Would you please send me a set of the templates as well.
:: :: :: :: :: Thanks
:: :: :: :: :: ::
:: :: :: :: :: ::
:: :: :: :: :: :: :: Dianne, # 0 prototype E 27, is having some work done. It
:: :: :: :: :: :: :: would be helpful to have templates or scale drawings for
:: :: :: :: :: :: :: the rudder profile. If you have these or know where they
:: :: :: :: :: :: :: could be found please contact me. SDK
:: :: :: :: :: ::
:: :: :: :: :: :: I have a set of templates and can send you some
:: :: :: :: :: :: full-size drawings from them if you can't find them in
:: :: :: :: :: :: the Bay Area. Let me know.