Tim,
I got the Gudgeons and pins from the local Nacra dealer (Key Sailing, Pensacola). That was the easy part.
Having access to a drill press is the best way to drill the castings. I did mine by hand. Not too bad, but would be easier with the press. I used brass (or bronze.. cant remember, been a few years ago

) tubing to bush the castings. I went in search of a size that would fit the rudder pin nice and snug (inside the tube). Then I drilled the casting the same size as the outer diameter of the tube. I pressed them in using a c-clamp and some epoxy. The epoxy was practically useless since most of it came off when I pressed the tubing in.

I think it did keep the corrosion down though. To date I still have not seen any corrosion. I sail primarily in the ocean and my boat stays at the beach under cover.
I'll see if I can get a digital camera to post a pic.
It is really simple..... You just cant rush it. There may be a better way and better material to use?

This was super cheap and easy though. After 5 years there is still no wear. About time for new gudgeons again though.
AJ
Nacra 6.0 Express