We are near the end of the planning and pricing stage of the Cal 40 Elliptical Rudder effort. The price has gone from $5,200 each to a current low of $1,373.33. (for 15 total ordered). There are three more potentials on the list, for a total, if everyone committed, of 18.
I am hopeful to bring the cost down a bit more working with Don Proul at FossFoam. Depending on the number actually ordered, he may reduce the Plug / Mold price. I have chosen to not reflect this at this time and have budgeted $1,373.33 per person per rudder, 15 total.
I am not charging any profit, and I am not in business to make or broker rudders. I have however coordinated a very affordable price for all of us to purchase directly a new rudder. With payments over a three-four month period.
Doug Grant of "Vang Master" has also invested innumerable hours researching this project. Doug can be contacted about his product at (310-831-2877). He also has a complete machine shop and can make shims and other parts. He is located near the "rake manufacturer" and Foss Foam, and is available to assist with some details, and provide inspections.
STEP 1. - First Payment Due. Early Feb.
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Purchase the design from Carl Schumacher.
Required: Your Check of $373.33 to:
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Carl Schumacher. NA
1921 Clement Ave. Bldg 13A Alameda, CA 94501
Re: Cal 40 Rudder
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The installment is comprised of $300 for your design royalty, and $73.33 towards the $1,100 design fee.
This is based on 15 rudders sold. If fewer rudders are sold, say 10, then an additional $36.67 would be asked for, to make $1,100.
If you cancel your order, or your rudder isn't made, Carl should refund you the $300 royalty. Mark your check note: $300 royalty; $73.33 Design.
STEP 2. - Second Payment Due: Late Feb / Early March
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Purchase the Plug & Mold Fabrication @ FossFoam
The amount will be determined by the number of Royalties Sold.
Checks will be mailed to:
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FOSSFOAM
849-C West 18th Street Costa Mesa CA 92627
Re: Cal 40 Rudder
Attention:
Don Proul (949)-646-0244
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Currently this is $200 for 15 rudders. This would be due when Carl Delivers the Design to FossFoam During Late Feb -Early March.
FossFoam may take up to one month to fabricate and complete.
Don will also be able to negotiate a better price on the Plug/Mold when he gets the Actual Royalty count. His high price is $3,000.
STEP 3. - Order your rudder
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Recap: Send in a check NOW to participate:
$373.33 to Carl Schumacher
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The Rudder Design Requirements Summary:
1. Replace in kind the existing Cal 40 rudder without modification.
2. Update the old design to a modern one (elliptical) to reduce stalling and
helm pressure.
3. Use sound materials and methods to provide long life and safety performance.
4. Minimize or negate any PHRF impact.. This is up to a committee, however, other Cal 40's with more radical rudder designs have not been hit with a penalty eg: Stan Honey's ILLUSION, Bill Partridge's "VICTORIA"
(no relation), both have Carbon Fiber Elliptical Rudders.
Email me if you have any questions.
Timm Lessley
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Cal 40, Cal 36
FYI:
After the Initial run, the mold will be "sold" to Vang Master for services rendered. The future cost as a "commercial product" will most likely increase.
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Kevin, et al.,
Thanks for your participation, once this gets started, it will go pretty fast.
I know of eight checks on their way to Carl.
The check to Foss Foam will happen in a couple of weeks on the outside. I will let you know, but for now plan near the end of February for the next installment.
New Information:
Carl has already begun the design, and may finish as early as this coming Monday Feb. 14th.
Carl's design is based on a 3" diameter TUBE shaft in the rudder, as indicated on
his sketches. He is aware that the original rudder shaft is 3" PIPE, (3.5" od). The
tube has the same mass/weight as the pipe, its smaller diameter allows a more
efficient rudder shape. The calcs for 3" od tube are well within the allowable
safety margin.
We have an option that I'd like to pole the participants about:
Solution 1. Sleeve top part of shaft to 3.5" using stainless. (Original Set-up)
Solution 2. Use UHMW plastic bushings top and bottom. (Modified set-up.)
At this point neither option effects the price, and neither one really adds any
difficulty to installation. The intent is that whatever we provide, comes complete.
and ready for installation. The metal sleeve gives us exactly what we have now,
metal against metal thrust bearing. If we choose the UHMW/Delrin then these items would be supplied with the rudder.
The UHMW provides a "frictionless" bearing surface (UHMW has a similar coefficient of friction as ice). Both Carl and Don Proul commented that this is
a common way to provide non ball bearing, bearing surface. Neither Don nor Carl have any concerns about longevity using the UHMW/Delrin Bearings.
Doug Grant of "Vang Master" is researching the Delrin/UHMW bearing, and if we go with this option he would most likely be manufacturing these parts, his Cal 40 is on the hard in his yard, he is near the proposed rake manufacturer so he can easily mock up the pieces.
I have proposed to Doug, that after the initial run of rudders, that he can take posession of the rudder mold, and sell rudders for profit after this run. In return, we would get the bushings at a nominal cost (Free?), Come on Doug! please?
I lean towards the Delrin Bearing insert... any questions/comments?
Don Proul is investigating the plug fabrication, it currently appears that he will select a company in the Bay Area, "Tuttle" of Water Rat that built parts for the AC boats, and Stan Honey's "Illusion" Cal 40 #57, The fastest Cal 40, ever, to Hawaii.
The company is next to Carl's office so he will be available to witness its form and direction personally. I like this!
Proposed rudder compared original Cal 40.
<<< Attachment deleted for list>>> if you want a copy let me know...
I'll send it direct.
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Update II
Our Elliptical Rudder Association (ERA) is 17 rudders strong!
Current ERA Listing:
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1.0 *Timm Lessley #94 "Victoria!" (PDX)
$1.4k for a new rudder.... and they caught it BEFORE it failed.. What would that failure have cost?
Okay, on to business. Many coordination issues are in progress, most will be invisible to you, but I want you to get the full story.
CARL SCHUMACHER/NA, UPDATE:
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Carl is complete with his work and is reviewing different options with us, as the design is "optimized" for fabrication. Carl is very impressed with our association and is willing to help out any way possible. Every optimization is reviewed and approved by Carl before proceeding. Most optimizations are regarding the rudder post.
FOSS (FOAM) COMPANY UPDATE:
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Don has gotten quotes for the rudder
parts and is working on the plug.
PLUG/MOLD UPDATE:
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Don will build for a Firm Price of
$3,000. This is the budget cost. Doug Grant of Vang Master, #59 "Encore", is trying to source another plug manufacturer, for comparison of price/time/quality.
RUDDER POST HAS (3) "OPTIMIZATIONS" IN PROGRESS;
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RUDDER POST OPTIMIZATION #(1) :
Using tube verses pipe reduces the rudder foil thickness (better foil design), and maintains strength requirements. The cost of 304ss tube (vs. pipe) raises the budgeted price $50; 316ss raises the price $75 per rudder, AT FOSS FOAM. [$800->$850; or $875].
The smaller post will require bushings to fit the original rudder tube. These will be provided with your rudder courtesy of Vang Master, as mentioned in previous updates. Thanks Doug!!!!
(see Bearing Update below)
BENEFITS: 304ss is stronger; 316 is more corrosion
resistant. Carl has used both materials, and both materials meet his strength requirements. Carl recommends 316 over 304, most rudder post failures he has seen are due to corrosion, particularly at the "joint" [see Rudder Optimization
(2)]. Typical stock rudders are 304ss for cost considerations.
I suggest the rudders be made of 316ss. To minimize cost impact Doug Grant is researching outsourcing the rudder post manufacture to see if we can get back into the original cost range.
RUDDER POST OPTIMIZATION #(2):
Two piece rudder post. To fit the rudder post within the foil at the lower end, Carl originally sleeved a smaller
tube in the 3" post at the lower end. Foss Foam prefers to use only one piece of 3" tube and flatten the tube as it approaches the thin section of the foil. Carl agrees
and actually prefers this, to having two pieces. As mentioned above Carl's withness'd failures happened at the corrosion at this sleeved location. A one piece shaft removes this possibility. There is no design strength concern, no cost impact, and overall corrosion resistance
is improved. We will proceed with this Optimization.
RUDDER POST OPTIMIZATION #(3):
Carl's original Rudder post had a one piece plate "flag" or tine to keep the foil from rotating on the post.
BEARING OPTIMIZATION:
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I have asked Mike Irish #40 "Madrugador" and Doug Grant #59 "Encore" to join up and resolve this issue. Mike is a Boeing Engineer
and has extensive materials knowledge on this topic. Doug has the machining facility and know how.
AWKWARD BUSINESS CONDITION:
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We are a little too successful!!
What I propose to do, and I think it is fair, is to continue collecting the costs as though there were only 15 rudders, and send the additional money to Doug at Vang Master. Doug
is performing R&D, manufacturing the rudder bushings, overseeing the post and plug design, and riding herd over Foss Foam.
So we are really adding a new vendor, with no cost impact to our original budget, and getting bearings and supervision for "free".
So what does this mean?, each person beyond 15 will send the $73.33 to Vang Master to help defray bearing fabrication for the rest of us. and $300 to Carl for the Rudder Royalty. There would be no $9.00 rebate checks.
Hopefully this meets with group approval, as I made a command decision and instructed the last two purchasers to proceed in this fashion. I realize I may have overstepped my bounds doing this, but I felt it was only fair.... and benefits everyone.
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Next update will instruct the amount to send to the plug/mold vendor. this should happen within a couple days... it has slipped a little because Doug is checking out alternate supply sources, which should be confirmed soon.
Best regards,
Timm Lessley
Update I
2.0 Jim Eddy #50 "Calisto" (LAX)
3.0 Gil Wood "Hooligan" (SEA)
4.0 Lynn Bantley #84 "Sirocco" (SFO)
5.0 Bob Bobbitt #12 "Pretty Lady" (SAN)
6.0 Rob Stigletz #32 "Bandit" (NYC)
7.0 Doug Grant #59 Encore (LAX)
8.0 Frank Dair #143 "Colloquy" (LAX)
9.0 Kevin Tisdall "Tumble Home"
10.0 *Bob Schaeffer (LAX)
11.0 *Skip Felmar #120 "Flying Cloud" (LAX)
12.0 David Cal 36 (MRY)
13.0 Jeff Turk Cal 36 (LAX)
14.0 Fin Beven #24 "Radiant" (LAX)
15.0 Christy Crawford #126 "Emily Ann" (SAN)
16.0 Chris Young #107 "Restless" (SAN)
17.0 *Mike Irish (Syn) #40 "Madrugador" (SEA)
The rudder effort is still growing, The Seattle boat Syndicate #40 "Madrugador" pulled the rudder for insurance inspection, Survey Says: $1-2k to repair a 35 year old rudder. Do you want
to use one of your three lifelines, is that your final answer?
*This is the fourth inspected rudder to show failure indications, including mine on #94 "Victoria!" My rudder had massive water intrusion via skin tears / cracks.
4 out of 17 = 23.5%! and that is all, (inspected and uninspected). The failure rate for "inspected" rudders is closer to 4 of 6 = 67% failure indication mode.
Foss Foam has suggested to use "standard" 4 pieces of 1/4"t x 4"w x 9"l stainless flat bar, instead of a custom fabricated piece. Carl has no issue with this approach, Foss indicates that using this standard method, keeps us withing the budget. I have not received what the cost of the custom plate would cost. With no design concerns, and indicated lower price, we will proceed with this Optimization.
Mike initially suggests a graphite impregnated Delrin material, which he has tested in the multi-million cycle range.
Our effort was based on 15 rudders being fabricated, Payments to Carl were made on this basis. We are now at 17 rudders, which means in theory each of us should be receiving a $9 rebate. I believe we will hit 20 rudders before the dust settles.
CLOSING:
Life Begins at Cal 40!
Cal 40 #94
"Victoria!"
Portland, Oregon
(503) 423-3998 x23671
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