I need collective wisdom to get a repair done to my rudder arms.

While I was pulling the boat ashore recently, I managed to snap both end caps that connect the rudder arms to the tiller crossbar.

I've got some spare rudder arms with good caps, so I duly drilled out the rivets. Now I find the caps on all of them are so corroded to the rudder arms that they don't budge. Vice grips and WD40 don't help. The way these are fused on, the rivets are superfluous!

So here's what I need your wisdom on: What can I use to loosen that corrosion and get the caps free? Can I soak them in something for a couple of days? Is it hopeless?

Thanks,

Al in Seattle

There must be some solvent you can use. Paint thinner or acetone might work, my friend got paint thinner to eat through the glass adhesive that held the halfs together of a sealed beam halogen light. also maybe an automotive degreaser. I've gotten alot of stuff loose that I never thought would come off that way, although it's hard to find a good degreaser. Some of them do little more than soap, but some will burn your hands if you dont wear gloves. one that i know is really strong is "purple power". it sounds fruity, yeah, but it will eat through just about anything other than the metal itself. You should be able to find it in an Advance Auto Parts or something like that.

oh yeah sorry I forgot, if you use any of those things i mentioned, soak it in them over night.

Here is a way that could work if the chemicals fail...
... Cut all of the casting off as close to the tiller as possible. From here you have tow options. 1. Drill a hole as big as possible in the end cap. If it is at least 10 mm in diameter you should be able to insert the blade of a "puk" saw (small version of a hacksaw - the bade is about 7 mm high). Cut a (or even better more than one) slot into the casting without cutting into the tiller. Once the tension is gone you should be able to get the pieces out. 2. Take a big punch or a socket and drive the old casting about 5 cm deep into the tiller - ignore it there - and just install your end caps or better one of those Hobie 20 conversion kits. As an afterthought - or a third option - Heat might help as well. Just heat it up and let it cool down a few times ... that might work it loose. I would try option 3 first.

Patrick

yeah the heat sounds like a good idea. Heat up the part on the outside so it will expand and then try to pull the other part out while the outside is still hot.